Annual Condition Checklist Template by Randy Pflanzer (rpflanzer@fssa.state.in.us) 

Inspection Details:



Location of Inspection:________________________ Date of Inspection:___________________



Aircraft Owner:______________________________ Total Airframe Hours:_________________



Mechanic:__________________________________ Total Engine Hours:__________________



Certificate Number:___________________________ Total Propeller Hours:_________________



Annual inspection Consumables:



- Oil filter (Champion CH48110) (Engine Lubrication Group)

- Oil (7 qts Phillips 20W50) (Engine Lubrication Group)

- Oil sample kit (Aviation Laboratories) (Engine Lubrication Group)

- Vacuum regulator garter filter (Airborne B3-5-1) (Cabin Mechanical Group)

- Vacuum system pleated filter (Airborne D9-18-1) (Cabin Mechanical Group)

- Hydraulic fluid (MIL-H-5606) (Engine Firewall Group)

- ELT batteries (6 – Duracell MN1300) (Cabin Electrical Group)

- ELT remote sensor battery (1 - Duracell DL 1/3 NB) (Cabin Electrical Group)

- K&N air filter recharge kit (K&N 99-5000) (Engine Intake Group)

- Brake lining replacement kit (Landing Gear Group)

- Stainless steel screws (22 – AN526C-832R8) (Propeller Group)

- Stainless steel screws (22 – AN526C-832R8) (Operational Inspection)

- Tire inner tubes (2 – 5:00X5-6IT) (Landing Gear Group)



Date/Time Installed Log:

Installed

- Tire inner tubes (replace every 3 years) June 2000

- ELT batteries (replace every 2 years) June 2000

- ELT remote sensor battery (replace every 2 years) June 2000

- Vacuum system pleated filter (replace every 500 hours) 0 hours



Engine - Propeller Group:



- Remove spinner noting alignment marks

- Remove propeller bolts and inspect for galling, cracks, etc.

- Inspect spinner and backplate for cracks or damaged nutplates

- Inspect crankcase nose seal for oil leaks

- Inspect propeller blades for nicks, cracks and/or surface erosion, repair as necessary

- Inspect hub for cracks and/or corrosion

- Re-install propeller mounting bolts, torque, and safety wire noting alignment marks

- Check propeller track

- Re-install spinner using new fasteners



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Engine - Cowling Group:



- Remove cowling joining screws, upper hinge pins, and remove upper cowling

- Remove lower hinge pins, side hinge pins, and remove lower cowling

- Inspect hinges for broken eyelets, excessive hinge and/or hinge pin wear

- Clean and inspect cowling for cracks and/or distortion

- Inspect lower cowling for damaged nutplates

- Inspect access doors and latches for operation and condition, lubricate



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Engine - Lubrication Group:


- Warm engine per oil sample instructions

- Drain oil sump and collect oil sample for analysis

- Remove, clean and inspect oil pump suction and pressure screens

- Remove, then replace spin-on oil filter and safety wire

- Inspect oil cooler fittings and lines for leaks and/or chafing

- Inspect oil cooler condition and door operation

- Inspect oil temperature sender for leaks and security

- Inspect oil pressure sender for leaks and security

- Inspect crankcase breather hose for security and obstructions

- Fill engine with new oil per lubrication chart



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Engine – Alternator Group:



- Inspect starter pinion, ring gear for wear and condition, lubricate w/grease

- Inspect propeller weights on ring gear for security

- Inspect starter mountings and lead connection

- Inspect alternator mountings and lead connections

- Inspect alternator condition

- Inspect alternator belt condition and tension



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________

Engine – Baffle Group:



- Clean/degrease engine, baffle and airseal gasket surfaces

- Inspect baffle fit and attachment fittings

- Inspect cooling tubes for security and seal

- Inspect baffles and airseal gaskets for condition



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Engine – Firewall Group:



- Inspect engine mount for cracks

- Inspect engine mount attachment nuts for security

- Inspect shock isolators, mounting bolts and washers for condition

- Inspect engine mounting bolts for security and torque

- Inspect brake fluid reservoir level, add fluid as required

- Inspect firewall for distortion and cracks

- Inspect firewall to engine ground wire for security and chafing

- Inspect all firewall penetration seals

- Inspect wire bundles for security and chafing

- Inspect vacuum pump and lines for security and condition

- Inspect accessories on rear case for security and leaks

- Inspect crankcase/sump for cracks, leaks and/or missing fasteners

- Inspect barrel base nuts for security

- Inspect rocker box cover gaskets for leaks

- Inspect shroud tubes for leaks

- Inspect inlet tubes for security and leaks

- Inspect exhaust system and mounting brackets for cracks

- Inspect exhaust gaskets for leaks and re-torque mounting nuts

- Inspect heat muffs, heat boxes and SCAT hoses for security

- Inspect cylinder head for bent fins and/or burned paint

- Measure warm WOT compression (PSIg)



1________ 2________ 3________ 4________





- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________________





Engine – Ignition Group:



- Remove plugs noting current installed location

- Inspect spark plug condition, clean and re-gap

- Rotate plug position/polarity, apply anti-seize and reinstall

- Inspect ignition harness, springs and insulators for condition

- Inspect magneto seals for oil leaks

- Inspect magneto mounting clamps/nuts for security

- Check LASAR magneto timing per LASAR instructions



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Engine – Fuel Group:



- Remove and clean gascolator screen and bowl

- Clean carburetor inlet strainer

- Inspect carburetor mounting nuts for security

- Inspect flexible fuel lines for condition and chafing

- Pressurize and inspect fuel system for leaks

- Inspect primer system for leaks



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Engine – Intake Group:



- Remove air inlet box and carburetor heat attachments

- Remove, clean and lubricate air filter

- Inspect throttle control cable attachment for condition and security

- Inspect throttle return spring for operation/condition

- Inspect mixture control cable attachment for condition and security

- Inspect mixture return sprint for operation/condition

- Inspect all engine controls for proper movement

- Re-install air inlet box and carburetor heat attachments

- Inspect carburetor heat door, SCAT tubing, and heat muff for operation and condition

- Inspect condition of ram air seal

- Inspect carburetor heat cable attachment for nicks and wear



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Cabin – Mechanical Group:



- Remove seats, seat backs, and interior panels

- Inspect wing attach bolts and nuts for proper torque

- Inspect condition of seat belts and shoulder harnesses

- Inspect fire extinguisher condition

- Inspect fuel selector valve operation, lubricate as necessary

- Inspect fuel lines in cabin for leaks and security

- Remove filter screen from FACET pump, clean, and re-install

- Pressurize and inspect fuel system for leaks

- Inspect ELT mount for security

- Inspect static air lines inside empennage for security and chafing

- Inspect fresh air vent lines for security

- Replace vacuum regulator foam filter

- Inspect vacuum lines, replace pleated filter if appropriate

- Inspect transponder, comm, and GPS antenna mounts and wiring for security

- Inspect empennage bulkheads and stringers for cracks and loose rivets

- Inspect GPS ball mount for security and condition



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



__________________________________________________________________



Cabin – Controls Group:



- Inspect elevator and aileron trim servo operation and display

- Inspect flap operation for binding

- Lubricate flap motor arm and all flap connecting rod ends

- Inspect rudder pedal operation and adjustment

- Inspect rudder pedals, cables and attachments

- Inspect brake masters and associated tubing for leaks

- Inspect control sticks, linkages and push/pull tubes 

- Lubricate rod ends for both elevator and aileron control tubes



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Cabin – Electrical Group:



- Inspect master/starter contactors and associated wiring

- Inspect instruments, lines and attachments

- Inspect instrument lights and rheostat for operation

- Inspect antenna connections and mounting

- Inspect behind firewall for loose wires and chafing lines

- Inspect wire bundles in empennage for security and chafing

- Inspect wire bundles under cockpit floor for security and chafing

- Inspect wire bundles underneath panel for security and chafing

- Inspect ELT batteries free from corrosion and in-service currency

- Verify ELT is armed

- Inspect battery is free from corrosion

- Inspect battery case is free from corrosion

- Inspect fuse panel for condition and wiring chafing

- Check altitude reporting encoder and certification

- Inspect spare fuses available in passenger seat back

- Re-install interior floor panels, seats, flap covers, and seat cushions 



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Fuselage Group



- Remove wing root fairings

- Inspect canopy structure and mounting points for security and wear

- Inspect canopy track for operation, lubricate rollers as necessary

- Inspect canopy latching mechanism for cracks and proper operation

- Inspect canopy and windshield for cracks

- Inspect static ports are clear

- Inspect skin for loose rivets, corrosion, and other damage

- Inspect fuel vent ports for security and condition

- Inspect drain holes are open



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Empennage Group



- Remove empennage fairing and fuselage inspection plates

- Inspect rudder and vertical stabilizer for corrosion and condition

- Inspect rudder pivot bolts for proper torque and lubricate

- Inspect rudder control stops for condition

- Inspect rudder cable attachments for security and cotter pin

- Inspect horizontal stabilizer and elevators for corrosion and condition

- Inspect elevator pivot bolts for proper torque and lubricate

- Inspect elevator counterbalance weights for security

- Inspect elevator control stops for condition

- Inspect elevator trim tab, arm, and actuator rod for cracks

- Inspect elevator bellcrank, horns and attachments for corrosion, security, and lubricate

- Inspect vertical stabilizer spar attach points for proper torque

- Inspect horizontal stabilizer spar attach points for proper torque

- Inspect electrical connections for security

- Reinstall inspection plates and fairings

- Inspect drain holes are open



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Tail Wheel Group



- Inspect tail wheel arm attach bolts for security and proper torque

- Inspect tail wheel steering springs for security and proper movement

- Remove tail wheel fairing and wheel assembly

- Grease tail wheel bearings

- Inspect tail wheel for uneven or excess wear

- Clean wheel and fairing of dirt

- Re-assemble and re-install tail wheel assembly



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Wing Group



- Remove inspection plates, landing light lenses, and strobe assemblies

- Inspect structure for corrosion and condition

- Inspect fuel tanks, lines and drains for leaks

- Inspect fuel vents not blocked

- Inspect fuel cap and O ring condition

- Inspect wing root attachment bolt for proper torque

- Inspect wing tank attachment bolt for proper torque

- Inspect fuel sender wiring for security and chafing

- Inspect strobe wiring for security and chafing

- Inspect wing tank attach screws for security

- Inspect aileron attach bolts for proper torque

- Inspect aileron control stops for security

- Inspect aileron trim tab and actuator rod for cracks and security

- Inspect aileron bellcrank for security

- Inspect aileron push tubes for condition and security of jam nuts

- Inspect ailerons for joint alignment in neutral position, adjust if necessary

- Lubricate all aileron rod ends

- Inspect flap system and attachments for slop

- Inspect flap torque tube and mounting plate for cracks/distortion

- Inspect flap actuator rod end and jam nut for security and lubricate

- inspect pitot tube and plumbing for security and blockage

- Inspect landing light fixtures for security

- Inspect strobe light wiring for security and chafing

- Inspect strobe unit attachment points for cracking and corrosion

- Inspect landing light for proper operation

- Clean and re-install landing light lens

- Inspect strobe and position lights for proper operation

- Clean and re-install strobe light assembly

- Reinstall inspection plates and fairings



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________________



Landing Gear Group



- Remove wheel pants and gear leg covers

- Remove tires and brake assemblies

- Inspect tires for wear and cracks, rotate if possible, replace if necessary

- Replace tire tubes if appropriate (every 3 years)

- Inspect brake linings for wear and condition, re-line if necessary

- Pack wheel bearings with grease 

- Fill tires with recommended air pressure

- Check brake cylinders for condition and leaks

- Check brake lines for security and chafing

- Thoroughly clean axle/brake area of dust 

- Re-mount wheels, tires, and brake assemblies

- Inspect wheel pant attach points for cracks and security

- Inspect gear leg covers for cracks and condition, re-install and secure

- Inspect wheel pants for cracks and condition

- Thoroughly clean wheel pants and re-install

- Inspect gear attach bolts for proper torque



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



Operational Inspection


- Visual inspection of engine/propeller

- All inspection panels and fairings secure

- Brake system check

- Check Boost Pump for Proper Pressure

- Engine start procedures

- Oil pressure/oil temperature within limits

- Vacuum check gauge

- Magneto check

- Ignition switch/both magneto’s grounded check

- Check alternator shut off/alternate buss operation

- Check fuel gauges for operation

- Check for proper idle RPM

- Check static run up

- Check RPM rise upon leaning mixture

- Check fuel selector for engine shutoff

- Cool down period after shutdown

- Inspect fuel, oil, and hydraulic systems for leaks

- Re-install cowlings, pins and new screws



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________





Documentation Group



- Verify Registration and Airworthiness Certificate in aircraft

- Verify Operating Limitations and State tax form in aircraft

- Verify pre-flight checklist and Pilot’s Operating Handbook in aircraft

- Verify external data plate secure and installed

- Verify EXPERIMENTAL placard installed in cockpit

- Verify PASSENGER WARNING placard installed in cockpit

- Review equipment list and update as necessary

- Review Airworthiness Directives for applicability

- Review Service Bulletin/Letter compliance

- Document condition inspection and record maintenance performed



- NOTES:________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________



_______________________________________________________________________________