Special Inspection Manual Cabin and Pressurized Structure

SPECIAL INSPECTION MANUAL
Cabin and Pressurized Structure
PA-42
PA-42-720
PA-42-720 (Advanced Trainer)
PA-42-720R
PA-42-1000
PA-42-1000 (Advanced Trainer)
PIPER AIRCRAFT CORPORATION

PART NUMBER 767-078 SEPTEMBER 15, 2009
Published by
Technical Publications
© 2009 Piper Aircraft, Inc.

2926 Piper Drive
Vero Beach, Florida 32960
U.S.A.
Original Issue: September 15, 2009
Member
General Aviation
Manufacturers Association
2
PA-42 / PA-42-720 / PA-42-720 (AT) / PA-42-720R / PA-42-1000 / PA-42-1000 (AT)
SPECIAL INSPECTION MANUAL - Cabin and Pressuized Structure
TABLE OF CONTENTS
SUBJECT PAGE
INTRODUCTION 5
Description 5
Definitions 5
Procedure 7
Program Responsibility 8
Forms 8
SPECIAL INSPECTION WORK SHEET 9

Cabin and Pressurized Structure Inspection 9
Operational Inspection 11
Inspection Completion 11
SAMPLE FORMS 27
Equipment Change and Overhaul Record 27
Discrepancy Record 28
Sep 15/09 3
THIS PAGE INTENTIONALLY BLANK
4 Sep 15/09
INTRODUCTION
1. Description
This Piper Special Inspection Manual provides a method of compliance with the Cabin and Pressurized
Structure inspections specified in:
Chart 401 in the PA-42 / PA-42-720 and PA-42-1000 maintenance manuals, and in the PA-42-1000
(Advanced Trainer) maintenance manual supplement; and,
4-00-00, Chart 1, in the PA-42-720 (Advanced Trainer) maintenance manual; and,
Chart 501 in the PA-42-720R maintenance manual.
This special inspection document is in addition to all other existing inspection information and should be
kept with those records.
The complete special inspection consists of an examination of the cabin and pressurized structure of the
fuselage to determine condition per Procedure, below. The remedy for unacceptable conditions will entail
the replacement or repair (as applicable) of those parts or structures which are found to be cracked,
damaged or otherwise in an unairworthy condition.
All inspections are visual (i.e., 10X magnifying glass); see AC43.13-1 (latest revision), Nondestructive
Inspection, Visual. Specific method/equipment used is either specified herein or at the discretion of the
inspector performing the particular task. Use of a borescope may be required to ensure complete access
to certain items being inspected. Chemical stripping of paint and primer may be required (at the
discretion of the inspector) as indicated by initial visual inspection. If parts are stripped for inspection,
reapply suitable protective coating(s) per AC43.13-1 (latest revision) before return to service.
Inspection may require the removal of parts and components; however, unless specifically noted in this
inspection, the structure will not be disassembled. Repair to parts or components may be accomplished
as specified in Chapter 51 in the appropriate maintenance manual or in accordance with AC43.13-1
(latest revision). Repairs may also be accomplished by the replacement of the unacceptable parts or
component parts with new Piper parts or components.
Discrepancies found during this inspection will be entered on the Discrepancy Record. The person
conducting the inspection will advise the owner and/or operator of the discrepancies found during the
inspection and entered on the Discrepancy Record. Discrepancies which affect the airworthiness of the
airplane will require the necessary corrective action to be accomplished before the airplane is returned
to service.
Late compliance with the special inspection may not exceed 50 hours time in service.
This inspection may coincide with the normal Piper Progressive Inspection event (see Piper Publications
under Definitions, below), or any Approved Inspection, as approved by the appropriate aviation authority.
(i.e. FAA, CAA, etc.)
2. Definitions
A. Inspections - Must be accomplished only by persons authorized by the FAA, 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.
Sep 15/09 5
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
components and systems at scheduled intervals in accordance with procedures approved by the
FAA under FAR Part 91.409(d) or Part 135.419.
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 a component from the aircraft to inspect for cleanliness, impending
failure, need for lubrication, repair or replacement of parts, and calibration to at least the
manufacturer’s specifications using the manufacturer’s 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’s
permanent records. The person performing the test must make appropriate entries in the aircraft’s
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.”
6 Sep 15/09
(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, as appropriate), are also factored into the calculation of service life limits.
NOTE: The owner/operator is responsible for recording and calculating life limiting cycles.
I. Piper Publications
(1) Illustrated Parts Catalogs (IPC)
(a) PA-42 / PA-42-720, P/N 761-717
(b) PA-42-720 (Advanced Trainer), P/N 761-818
(c) PA-42-720R, P/N 761-804
(d) PA-42-1000, P/N 761-792
(e) PA-42-1000 (Advanced Trainer) Supplement, P/N 761-842
(2) Maintenance Manuals (MM)
(a) PA-42 / PA-42-720, P/N 761-523
(b) PA-42-720 (Advanced Trainer), P/N 761-852
(c) PA-42-720R, P/N 761-803
(d) PA-42-1000, P/N 761-789
(e) PA-42-1000 (Advanced Trainer) Supplement, P/N 761-840
(3) Progressive Inspection Manuals
(a) PA-42 / PA-42-720:
1 50 Hour Events, P/N 761-760
(b) PA-42-720 (Advanced Trainer):
(c) PA-42-720R:
(d) PA-42-1000:
(e) PA-42-1000 (Advanced Trainer):
3. Procedure
This special inspection consists of the following two separate inspections: a complete inspection at the
first required inspection interval; and, a followup inspection of two items at the second required
inspection interval. See the appropriate maintenance manual for actual inspection times.
NOTE: All inspections are visual.
A. At the first required inspection interval, conduct the inspections specified in the Special Inspection
Work Sheet, below.
B. At the second required inspection interval, inspect only Items (12) and (15), Figure 3, in the Special
Inspection Work Sheet, below.
Sep 15/09 7
4. Program Responsibility
Refer to the program responsibility criteria outlined in the standard inspection program being used. All
requirements remain in effect.
5. Forms
A. Equipment Change and Overhaul Record (see page 27)
Information contained in the Equipment Change and Overhaul Record for this inspection must be
maintained with the Equipment Change and Overhaul Record listed in the standard inspection
program being utilized.
B. Discrepancy Record (see page 28)
Information contained in the Discrepancy Record for this inspection must be maintained with the
Discrepancy Record listed in the standard inspection program being used.
8 Sep 15/09
AIRPLANE REGISTRATION FUSELAGE

SERIAL NUMBER NUMBER SERIAL NUMBER
SPECIAL INSPECTION WORK SHEET

(Sheet 1 of 17)
NOTE: References to chapter (Chapter 27) or section (5-10-00) herein are to the corresponding
Chapter or Section in the appropriate maintenance manual (see Piper Publications under
Definitions, above).
NOTE: Refer to the applicable chapter of the appropriate maintenance manual as required to
accomplish removal, installation, adjustment, rigging, and testing specified herein.
NOTE: Remove parts and components as required to conduct the following inspections; however,
unless specifically noted, do not disassemble the structure.
CABIN AND PRESSURIZED STRUCTURE INSPECTION

The following inspections are all visual for cracks. Use of a borescope may be required to achieve
complete access to the parts being inspected. Figure 1 shows the types of cracks likely to be
encountered. Chemical stripping of paint and primer may be required (at the discretion of the inspector)
as indicated by initial visual inspection.
NOTE: Item numbers are keyed to Figures 2 thru 13.
L R
NOTE: See Figure 2 for the following items.
1. Remove cabin door per 52-10-00.
2. Remove cabin door forward and aft panel assemblies.
3. Inspect the cabin door bulkheads (Items 1 and 2).
4. Reapply protective coating(s) to any part previously stripped for inspection.
5. Install cabin door forward and aft panel assemblies.
6. Install cabin door per 52-10-00.
7. Place a tail stand under the airplane tail (see 7-10-00).
8. Remove seats and interior furnishings, interior panels and floorboards, and insulation as
required to expose cabin / fuselage structure.
9. Inspect the attachment angle (Item 3).
10. Inspect the attachment angle (Item 4).
11. Inspect the pilot’s side window frame lower channel, Item 5.
12. Inspect the fuselage bulkhead assembly (Item 6) at fuselage station (F.S.) 110.38.
13. Inspect the fuselage bulkhead (Item 7) at F.S. 117.88.
Sep 15/09 9

(Sheet 2 of 17)
CABIN AND PRESSURIZED STRUCTURE INSPECTION (continued)

L R
19. Inspect the attachment angle (Item 10) at the forward end of the window frame upper channel,
F.S. 117.88–140.00.
20. Inspect the attachment angle (Item 11) at the forward end of the window frame lower channel,
F.S. 117.88–140.00.
21. Inspect the window frame lower channel (Item 12), F.S. 117.88–140.00.
22. Inspect the window skin doubler (Item 19), F.S. 117.88–140.00.
24. Inspect the window frame upper channel (Item 14), F.S. 148.62–170.08.
25. Inspect the window frame upper channel (Item 14), F.S. 184.12–206.37.
26. Inspect the window frame bulkhead (Item 18) at F.S. 184.12.
NOTE: See Figure 4 for the following item.
28. Inspect the forward lower fuselage stringer (Item 20).
NOTE: See Figure 5 for the following item.
29. Inspect the channel (Item 21) on the forward side of the forward pressure bulkhead.
30. Inspect the center bulkhead assembly (Item 22) at F.S. 72.25.
31. Inspect the beam assembly (Item 23) for cracks in the web between F.S. 57.00 and F.S. 76.00.
32. Inspect the fuselage channel (Item 24), F.S. 57.00–110.38.
34. Inspect the bulkhead assembly (Item 26) at F.S. 87.50.
44. Inspect the clip (Item 36) at the forward end of the fuselage channel, F.S. 174.00–181.00.
10 Sep 15/09

(Sheet 3 of 17)
L R
NOTE: See Figures 9 and 10 for the following items.
47. Inspect the top bulkhead (Item 39) at F.S. 270.00.
51. Inspect the cabin door seal support plate assembly (Item 43).
52. Inspect the cabin door sill (Item 43A).
53. Inspect the bulkhead assembly (Item 44) at F.S. 280.00. Be sure to inspect both the inner and
outer frames.
58. Inspect the shelf (Item 49) attached at W.L. 23.12 to the aft side of the bulkhead assembly at
F.S. 332.00.
59. Inspect the fuselage skin (Item 50), F.S. 117.88–215.00, W.L. -14.75–30.75; from inside and out,
at rivet locations, window cut-outs, and any penetration.
60. Inspect the fuselage top inner skin (Item 51), F.S. 110.375–117.88; from inside and out, at rivet
locations and any penetration.
61. Inspect the fuselage inner skin (Item 52), F.S. 110.375–117.88; from inside and out, at rivet
locations and any penetration.
62. Inspect the strap (Item 53) at W.L. 10.00.
63. Inspect the strap (Item 54) at W.L. 10.00.
64. Reapply protective coating(s) to any part previously stripped for inspection.
65. Reinstall seats and interior furnishings, interior panels and floorboards, and insulation, if
removed to expose cabin / fuselage structure.
66. Remove tail stand from under the airplane tail (see 7-10-00).
OPERATIONAL INSPECTION
Complete the Operational Inspection portion of the inspection program routinely used to maintain the airplane.
INSPECTION COMPLETION
Make an entry in the aircraft log book indicating that this Special Inspection has been accomplished.
Otherwise, enter this information in the Event Inspection Record and Sign-Off Sheet, if appropriate. The
Sign-Off Sheet must contain the following:
A. Event Inspection Number (if coinciding with an Event Inspection),
B. Aircraft Hours,
C. Date Accomplished,
D. Work Order Number - FAA approved repair stations or equivalent,
E. Signature and Certificate Number of person conducting inspection, and
F. A statement certifying Inspection Completion and approval for return to service (see Sheet 17).
Sep 15/09 11

(Sheet 4 of 17)
Types of Cracks
Figure 1
12 Sep 15/09

(Sheet 5 of 17)
Cabin and Pressurized Structure Inspection

Figure 2
Sep 15/09 13

(Sheet 6 of 17)

Figure 3
14 Sep 15/09

(Sheet 7 of 17)

Figure 4
Sep 15/09 15

(Sheet 8 of 17)

Figure 5
16 Sep 15/09

(Sheet 9 of 17)

Figure 6
Sep 15/09 17

(Sheet 10 of 17)

Figure 7
18 Sep 15/09

(Sheet 11 of 17)

Figure 8
Sep 15/09 19

(Sheet 12 of 17)

Figure 9
20 Sep 15/09

(Sheet 13 of 17)

Figure 10
Sep 15/09 21

(Sheet 14 of 17)

Figure 11
22 Sep 15/09

(Sheet 15 of 17)

Figure 12
Sep 15/09 23

(Sheet 16 of 17)

Figure 13
24 Sep 15/09


(Sheet 17 of 17)
INSPECTION COMPLETED
I certify that this airplane has been inspected in accordance

with Piper’s:
First or second Special Inspection

(Circle One)
for
the Cabin and Pressurized Structure
and is approved for return to service. Pertinent details of this
inspection are on file at this facility under:
Repair Order No.
Total Time: Date:
Signed: Repair Station No.:
Sep 15/09 25
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26 Sep 15/09
Sep 15/09

EQUIPMENT CHANGE
AND OVERHAUL
RECORD

DATE A/C REMOVED PART NO. SERIAL INSTALLED PART NO. SERIAL SIGNATURE AND CERTIFICATE NO.
HOURS NUMBER NUMBER

27
DATE
CERTIFICATE NO.
SIGNATURE AND
SERIAL NUMBER
FUSELAGE
W.O.#
CORRECTIVE ACTION
REGISTRATION
NUMBER
DATE
SERIAL NUMBER
AIRPLANE
SIGNATURE
DISCREPANCY RECORD
HOURS
A/C
DISCREPANCY
28 Sep 15/09

Special Inspection Manual Cabin and Pressurized Structure

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SPECIAL INSPECTION MANUAL

Cabin and Pressurized Structure

PIPER AIRCRAFT CORPORATION

© 2009 Piper Aircraft, Inc.

Original Issue: September 15, 2009

SPECIAL INSPECTION WORK SHEET 9

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AIRPLANE REGISTRATION FUSELAGE

SPECIAL INSPECTION WORK SHEET

CABIN AND PRESSURIZED STRUCTURE INSPECTION

SPECIAL INSPECTION WORK SHEET

CABIN AND PRESSURIZED STRUCTURE INSPECTION (continued)

SPECIAL INSPECTION WORK SHEET

SPECIAL INSPECTION WORK SHEET

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

SPECIAL INSPECTION WORK SHEET

Cabin and Pressurized Structure Inspection

AIRPLANE REGISTRATION FUSELAGE

SPECIAL INSPECTION WORK SHEET

I certify that this airplane has been inspected in accordance

First or second Special Inspection

Repair Order No.

Total Time: Date:

Signed: Repair Station No.:

THIS PAGE INTENTIONALLY BLANK

AIRPLANE REGISTRATION FUSELAGE

PA-42 / PA-42-720 / PA-42-720 (AT) / PA-42-720R / PA-42-1000 / PA-42-1000 (AT)

SPECIAL INSPECTION MANUAL - Cabin and Pressuized Structure

PIPER AIRCRAFT CORPORATION

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