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pre-purchase inspections
pre-annual-inspection run-up
annual inspection check list
100 hour check list
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little flyers engine 100 hr inspection check list 3/7/99

16 airport drive, kearny, arizona 85237

520-363-5175

format based on jasc code dated 1/30/96 & ata code

revised 1/20/2000

 

wo#______  client __________________________________    date _____________

 

n_________ aircraft mfr._________model________________  sng lh rh fwd aft

 

l tach ________ r tach ________         hr. meter______ att______

 

tcm lyc model _____________ sn __________ ett__________tsmo ___________

 

note: this check list is not exhaustive and does not supersede manufacture�s publications!

 

items requiring inspection / service / replacement at other than normal 100 hr. / annual intervals are in italics

 

1. engine general status

7000   power plant 100 hr. inspection       7004   service letters

7001   special inspections due                  7005   service instructions

7002   airworthiness directives                  7006   life limited parts

7003   service bulletins                              research by ________________________

2. inspection preparations

perform maintenance run-up, record, enter discrepancies ____ protect aircraft finish ___  

compression checks by ______    1          2          3          4          5          6

differential top of stroke / 80 psi   ______ ______ ______ _____ _____ _____                  

differential bottom of stroke /80   ______ ______ ______  _____ _____ _____

simultaneous direct compression______ ______ ______  _____ _____ _____

 

3. oil drain, filter / screen inspection

oil drain , sample                                          inspect oil pressure screen, clean, reinstall

install plug with news gasket, torque, safety                       with new gasket, safety

oil filter inspection, magnetic wash            inspect oil suction screen, clean,

install new filter pn: _______ safety wire               reinstall with new gasket, safety

                                                                        completed by _________ insp. _________

preliminary inspection / considerations

pressure test exhaust system / muffler / heat exchanger / turbo components

remove and ship out items requiring outside repairs / service.

                                                                        completed by _________ insp. _________

 
air conditioning

2150   air conditioning compressor,        belt tension                            ___________

mounting, refrigerate lines / hoses,                       2910   hydraulic pump / lines / hoses

drive, clutch, idler, belt,                               completed by _________ insp. _________

primary / #1  alternator

2434   alternator / housing / security /       terminals, wiring, boots, filter

brushes / slip ring / bearings, seal /                      cooling, rain shield

alternator out sensor                                   drive, idler, belt tension _______

primary alternator 5 yr. / 300 hr. gear drive / 500 hr. belt drive internal insp./ lube  ___

(aerobatic gear drive alternator 100 hr   completed by _________ insp. _________

 #2  alternator

2434   alternator / housing / security /       terminals, wiring, boots, filter

brushes / slip ring / bearings, seal /                      cooling, rain shield

alternator out sensor                                   drive, idler, belt tension _______

primary alternator 5 yr. / 300 hr. gear drive / 500 hr. belt drive internal insp./ lube  ___

(aerobatic gear drive alternator 100 hr   completed by _________ insp. _________

 
primary generator

2434   generator / housing, brushes,        drive, idler, belt tension _______________

bearings, commutator, mounting, cooling            300 hr. generator internal inspection

terminals, wiring, boots, filter                   completed by _________ insp. _________

stand-by generator

2434   generator / housing, brushes,        drive, idler, belt tension _______________

bearings, commutator, mounting, cooling            500 hr. generator internal inspection

terminals, wiring, boots, filter                   completed by _________ insp. _________

 

fire protection

2610   detection system                              2620   extinguishing system discharge tubes                                                                              completed by _________ insp. _________

hydraulic

2910   hydraulic / lines / hoses _____     2913   engine drive pump / mounting / drive 

completed by _________ insp. _________

ice and rain protection

3060   prop anti/de-ice system engine area         3025   thrust detector heat             

            completed by _________ insp. _________

 

pneumatic

3605   air pump(s) / cooling shroud(s)      3630   oil separating

3610   distribution hoses                            3640   pump inlet filtration

carbon vane inspection 300+ hrs________       completed by _________ insp. _________

 

vacuum

3705   vacuum pump(s) / cooling shroud 3707   oil separating                                   

3706   induction stand-by system                3710   distribution / manifold(s) / hoses

carbon vane inspection 300+ hrs________       completed by _________ insp. _________

 
engine cowling

7111   cowl flap / system                             7114   cowling skin

7112   cooling baffles / seals                     7115   latches/fasteners /chafe protection

7113   cowling structure                              7116   access doors

                                                                        completed by _________ insp. _________

 
engine mounting

7121   engine mounting structure               7123   damper / mount heat shields

7122   flex vibration dampners / orientation         7128   electrical bonding

completed by _________ insp. _________

 

firewall

7131   firewall / sealing                              completed by _________ insp. _________

engine electrical

7151   electrical harness / protection         completed by _________ insp. _________

 

engine air intake

7161   air inlet / duct                                     clean paper filter(s), replace at 500 hrs.

7162   air inlet coupling / boot / flex duct    7166   ram air / housing / valve

7165   filter(s) install new foam element(s)          completed by _________ insp. _________

 
engine drains / vents

7172   crankcase breather / ice relief hole            7174   accessory drain(s)

remove carbon at exhaust junction                        7175   system vent(s)

7173   induction manifold drain(s) / valve(s)

clean and inspect each 300 hrs.               completed by _________ insp. _________

 

basic engine

7210   front section / reduction gearing   7231   400 hr / mid life valve inspection

7220   crankcase / crank / seal / retainer  7232            push rod shrouds / rocker covers

crankshaft rf @ 30� st.: ____ lbs.                      7234   dry valve lash clearance spec ____

crankshaft end play spec ____ actual ____         7235   tappets, spec. in ____ ex ____   

7230   cylinder assembly                            7240   accessory drive  / starter drive

lycoming si 1129a accessory drive belt tension

new 3/8�         11-13 ft/lbs     132-156 in/lbs           used 3/8�        7-9 ft/lbs         84-108 in/lbs

new ��           13-15 ft/lbs     156-180 in/lbs           used ��          9-11 ft/lbs       108-132in/lbs

completed by _________ insp. _________

 
fuel distribution

7310   engine fuel distribution / lines /  hoses

replace not-teflon fuel hoses each 5 yrs, rayjay system, 8 yrs other installations

7326   engine fuel system cooling / heating          completed by _________ insp. _________

 

injection fuel metering

7313   fuel injector nozzle                           tcm sid 97-3 injection adjust @400 hrs

clean nozzles, flow check at 250 hrs        ad93-02-05 lycoming fuel injection lines

normally aspirated / 500 hrs. turbo ____  i/a/w installation i/a/w diag. # _________

7314   engine fuel pump / cooling              replace diaphragm pumps @ 20 yrs

7315   primer system / diverter valve         overhaul diaphragm fuel servo @ 20 yrs

7325   fuel injection system                                    7320   system fuel filtration / clean

tcm sb 95-7 manifold valve cover insp.   completed by _________ insp. _________

 

carburetor fuel metering

7314   engine fuel pump / cooling                          drain flush carb bowl

replace diaphragm pumps @ 20 yrs.      check bowl fuel level

7315   primer system / diverter valve         inspect  ma4 metal floats @ 1000 hrs

clean primer nozzles at 300 hrs.              oh diaphragm pressure unit @ 20 yrs.

7322   carburetor / mounting                                   7325   inspect / clean fuel inlet screen

completed by _________ insp. _________

 
engine ignition

7413   starting ignition

shower of sparks / slick start /  wiring     500 hr. impulse coupling inspection

start timing spec _____  actual _____      single _____   lh ______ rh ______

completed by _________ insp. _________

 

7414   magneto(s)

magneto housing(s), mounting                   plugs / vents / �p� leads

internal timing / cam symmetry                  blast tubes / cooling shrouds

timing btc spec lh ____ rh ____           actual lh ____  rh ____ (tcm msb 94-8)

500 hr / 5 yr. magneto internal inspection / lubrication       lh ____  rh ____

                                                completed by _________ insp. _________

 

7415   magneto pressurization filter(s)

replace when contaminated /  200 hrs / 2 years  completed by _________ insp. _________

 

7420   ignition harness

ignition harness / shielding / grounding     terminals / insulators / seals / springs

routing, support                                           completed by _________ insp. _________

 

7421   spark plugs

spark plug part # ____, verify application            clean terminal wells, rotate per chart

cleaned, inspected, gapped to ____ in.    install new gaskets, torque _____ in / lbs.

erosion gauged, tested, painted                 completed by _________ insp. _________

 

7430   ignition switching

�p� leads / security                                       start wiring / functional check

verify ignition switch functions, non retarded

magneto to be inop in start position.                      completed by _________ insp. _________

 
air

7510   carb heat / alternate air / ram air    7511   induction/ seals/ couplings / clamps

                                                                        completed by _________ insp. _________

 

engine cooling system

7521   cooling baffles / ties / supports     7523   winterization baffles

7522   baffle seals                                        completed by _________ insp. _________

 
engine controls (engine compartment area)

7600   c/w tcm sb 95-2 engine control / linkage inspection   

7601   prop synchronizing                           7605   alternate/ ram air / carb heat

7602   mixture control                                   7606   turbo waste gate (non automatic)

7603   throttle control                                   7607   cowl flap control

7604   prop governor control                                   completed by _________ insp. _________       

 
engine indicating (engine compartment area)

7713   manifold pressure / hoses               7723   carb air / cdt / intercooler temp

7714   tachometer                                       7728   fuel pressure/ flow indicating/ hoses

7719   oil pressure / hose                           7729   fuel pressure / flow transducer

7720   oil temperature                                 7740   engine analyzer / graphic monitor

7721   cylinder head temperature              7745   engine thrust detector system

7722   exhaust / turbine inlet temperatures     completed by _________ insp. _________

 
engine exhaust

7810   collectors / risers / runners                       7822   overboard stack / hangers / braces

7815   slip joints / clamps / ball joints /     7824   heat shields / deflectors

springs / restraint link(s)                             7826   life limited components

7820   muffler / heat exchanger/                 safety wire �v� band type clamps

flame tubes / shrouds                                 completed by _________ insp. _____

engine oil

7910   reservoir / sump / cap /                  7921   oil cooler(s) / plumbing / mounting .

chain / markings                                           7922   temperature regulator

7912   drain valve / plug / safety                 7925   filter / pressure screen

7916   oil scavenge / check valve(s)       7926   pump / relive valve / suction screen

7918   crank case breather oil separator  7932   oil quantity (level gage / calibration)

clean breather separator and oil return line          7934   inverted oil system / hoses

7920   oil lines / hoses / rocker drains /   7935   pre heater(s)

couplings.                                                      7940   pre oiler / hoses

replace rajay system hoses @ 5 year intervals (ad), replace hose pipers with fwd oil coolers  @ 5 year intervals.               replace other non teflon hoses at 8 year intervals. 

others 8 yr. intervals                                                completed by _________ insp. _________

 
8011   starting

starter / mounting / brushes / commutator            manual engage arm, return spring

cable / lug / boot / contactor & diode     mid life internal inspection / lubrication

drive gear / ring gear / mesh / clearance            completed by _________ insp. _________

 
engine turbo charging

8120   turbocharger(s) / mounting /                        reseal actuators(s) @ 1000 hrs / 10 yrs

turbine(s) / compressor(s) / heat shields 8124   turbo controller(s)  / relief valve

8121   lubrication system / reservoirs /    8125   turbo compressor discharge /

lines / in/outlet check valves / hoses       deck pressure / couplings / ducts /

clean / inspect reservoirs, oil inlet and       trap doors / seals / deck lines / hoses 

scavenge check valves @ 1000 hrs/10 yrs          8126   intercooler(s)

8122   waste gate(s)/ return spring                       8127   life limited turbo exhaust parts

8123   wg actuator / manual controls(s)    completed by _________ insp. _________

 
propellers

6105   propeller / governor ad�s                6114   propeller hub

6110   propeller assembly / lubrication     6121   propeller synchronizer / phaser

6111   propeller blade / dress / paint        6122   prop governor / lines / hoses

6112   propeller de-ice boot section                      6123   prop un-feathering / lines / hoses

6113   propeller spinner section                 completed by _________ insp. _________

servicing

1200   cleaning                                             1220   oil __________ qts. __ additive ___                                                                                completed by _________ insp. _________

nitrogen

1260   propeller dome                                 1261   prop un-feather accumulator             

                                                                        completed by _________ insp. _________

 

inter system dress inspection

inspect all engine controls, wiring, & plumbing for routing, interference between systems, and security.                                                       completed by _________ insp. _________

 miscellaneous

items not covered by �check list�   _____ correct any discrepancies   ___________

pressure inspect engine fuel system

�pre cowl� inspection completed    _____             complete documentation     ___________

post insp. leak & function run (short          _____ date completed                   ___________

clean, cowl, close up                                    _____ amt signature / # ____________________

cowling inspection                           _____             amt signature / # ____________________

post inspection run-up, record        _____             inspector ___________________________

this document is property of little flyers and may not be reproduced without written permission!  

 

old airframe annual / 100 hour check list


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last modified: february 26, 2007

 

 

 

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