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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 / CONSIDERATIONSPressure
test exhaust system / muffler / heat exchanger / turbo components Remove
and ship out items requiring outside repairs / service.
Completed by _________ Insp.
_________ AIR
CONDITIONING
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 Protection3060
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 ELECTRICAL7151
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 METERING7313
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. _________ Nitrogen1260
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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