Maule 100 Hour/Annual Inspection Checklist
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MAULE 100 HOUR/ANNUAL INSPECTION CHECKLIST Powerplant/Firewall Forward • Preparation: Warm engine, preferably by flying until at operating temperature. • Cowl: Remove top and bottom cowl. Inspect for cracks or other damage and repair as needed. • Leaks and cleanliness: During all steps below, be looking for signs of leaks. Clean entire engine and firewall as you go, or at some point during process or at end. • Oil: Start oil draining, complete compression check (next step) then clean sump screen (do not remove unless oil drained), replace oil filter, and refill oil. Sump screen crush washer is Lycoming part # 06E19769-1.00 or MS 35769-21. • Compression: Remove top or bottom spark plugs and test compression. • Magnetos: Check history to determine if due for service. Set magneto-to-engine timing. • Plugs: Clean and re-gap (spec is .016”- .021”). Check inside of wire connection area for signs of arcing. Rotate top to bottom, unless using fine-wires in bottom only. Reinstall top plugs, but do not reinstall bottoms until valve train step completed. If using Champion plugs, do NOT bother to check resistance, as the resistor type in these plugs can only be properly checked under very high voltage. Readings from a handheld ohmmeter are meaningless in this case. • Plug wires: Check carefully for signs of damage. Check plug ends (“cigarettes”) for cracks and signs of arcing. • Valve train: Every 400 hours, remove rocker box covers. Check for cracks on rocker shaft bosses. Check operation of pushrods and rocker arms for proper operation while rotating engine. Check for proper oiling. If not removing covers, check screws for torque. • Crankcase: Inspect for cracks. This is a good time to clean as you inspect. • Injectors (if fuel injected): Remove and clean if blockage suspected. • Fuel lines: Check all hard fuel lines for mounting security, cracks, and signs of rubbing wear, particularly around and under Adel clamps. Pay particular attention to fuel lines going into cabin, such as for pressure gauge. • Fuel filter: Check and clean fuel filter in injection unit (accessed at left side of unit, where fuel inlet hose attaches) or carburetor. • Fuel hoses: Check all flexible fuel hoses for security, chafing, and damage. • Gascolator: Turn off fuel valve. Remove bowl, drain and clean. Remove and clean filter. • Induction system: Check air filter, and replace if necessary. Check airbox for cracks, and check function of alternate air. • Oil hoses and lines: Check all for condition, chafing, cracking, etc. • Oil breather line: Check mounting security and condition. • Oil cooler: Check mounting security and general condition. Check for debris in fins, and general condition of fins. • Hardware: Check all case half perimeter, accessory case, and oil pan bolts for security. • Clamps: Check all clamps for tightness. • Manifold Bolts/nuts: Check intake and exhaust manifold bolts for tightness. • Mufflers: Remove heat muffs and inspect for cracks in muffler, and general condition of heat muffs. • SCAT hoses: Check for condition. Secure as needed from vibration wear with zip ties and/or silicone. • Baffles and baffle seals: Check baffles for cracks, wear, and security. Check seals for condition and security. • Engine mount: Check for cracks, bending, wear, and corrosion. Check particularly under any zip ties, etc. • Engine mount bolts: Check torque of all bolts, both to engine, and to airframe (15 ft. lbs mount- to-airframe; 40 ft. lbs. mount-to-engine). Check condition of mount bushings. Easiest to do lower mount-to-airframe bolts while rudder bar cover and side panels are removed for fuselage section work. • Controls: Check all engine controls for proper operation. Check condition and security of cables. • Electrical: Check security of all wires and their connections. Check for chafing, cracking of insulation, or other damage. • Alternator: Check security and condition of mounts. Check wiring connections. Consider checking brush wear, depending on use (1/2” long new; wear limit is ¼”). • Alternator Belt: Check for cracks and proper tension. • Starter: Check mounting security. Check wire attachments. • Heat/Vent: Check operation of all heater and ventilation valves. • Firewall seals: Check condition and re-seal as needed. Wings • Skins: Inspect main wing and control surface skins for cracks, missing or pulled rivets, etc. • Hinges: Check aileron and flap hinges for excess play. • Actuation Rods: Check for play, bending, etc. • Wing interior: Check ribs, spars, etc., for cracks, deformation, and corrosion. • Control surface supports: Inspect flap and aileron supports for bending, cracks, and security. • Cables: Check for proper routing, wear where they run over pulleys and through fairleads. • Cable ends: Check for proper swedging. • Pulleys: Check for general condition, wear, excess play, and mounting security. • Cable tension: Check aileron cables for proper tension (most easily done in cabin, above headliner). Note that there are actually two “loops” in the aileron cable system; one to the ailerons, one to the controls. These are joined in the top of the cabin. Check tension on both loops. • Control surface travel: Check flap and aileron travel with angle finder. • Fuel tanks: Check for leaks or cracks. Inspect fuel line connections at auxiliary tanks for security. • Vent tubes: Inspect for kinks, blockage, etc. • Fuel caps: Inspect for general condition, and check cap gaskets for dry-cracking. • Wiring: Check wiring inside wing for general condition, routing, and chafing. • Wingtips: Check general condition and mounting screws. • Struts: Remove strut fairings and check for AD compliance, general condition, and mounting bolt security. • Lights: Check function. • Aux tank pumps: Clean auxiliary tank fuel transfer pump screens. Check and clean magnet in bottom cup. Test-run pumps. • Wing root area: Remove top half of front wing root fairings, flop top fairing back, and remove duct tape from forward eight inches or so. Check security of wing attach hardware. Can check rear bolt torque paint through lower inspection hole in wing. Check fuel hose condition and clamp tightness (two hoses each wing). Forward hose is located just behind front spar, and is inspected through top fairing. Rear hose is inspected through headliner zipper. Note that access to the hose clamps is difficult. Check for clamp looseness with finger. If no reason to suspect problem, no need to go to effort of getting a wrench on them. The clamp on the fuselage end of the forward hose is inaccessible without significant disassembly. Hoses/Clamps canNOT be easily accessed by removing stainless trim at top of door opening, as the headliner is glued to airframe under that trim. Re-tape before reinstalling fairings. Rear fuel hose can be inspected through zipper in headliner. Also, lube aileron cable pulley at top of windshield post while in here. • Stall indicator: Check function. • Antennas: Check security and cables. • Pitot heat: Test operation. • Lubrication: Lube hinges and pulleys. Easiest to use liquid oil in a Zoom Spout bottle, a syringe, or something similar instead of aerosol. Much neater. Tail • Fabric: Inspect all horizontal and vertical surfaces for fabric and paint condition. • Structure: Check for bent or dented tubes, etc. under fabric. • Hardware: Check all attaching hardware, horns, and stops for condition and security. • Elevator: Check hinges for security and excess play. Check for play between the two elevator halves (push one down while pulling the other up, and vice-versa). • Trim tab: Check wear of pivots, security and condition of cables. • Horizontal Stabilizer struts: Remove struts and inspect for general condition. • Horizontal Stabilizer Struts Mounting Stubs: With struts removed, check carefully for corrosion, or degradation of sealant inside stub. If necessary, remove sealant to properly inspect. Replace with silicone once any corrosion has been removed and treated. • Rudder: Check hinges for security and excess play. • Rudder servo tab: Check wear of pivots, security and condition of cables. • Cables: Check for proper routing, wear where they run over pulleys. Check to ensure that no bending loads are imparted to attachment points or turnbuckles over entire range of travel of control surfaces. • Cable ends: Check for proper swedging. • Control surface travel: Check elevator, rudder, and trim tab travel with angle finder. • Corrosion: Check entire tail area (especially tubes at bottom rear of tail, bottom of rudder, and control cable hardware) for corrosion. • Tail light: Check function; inspect wires for routing, chafing, general condition. • Lubrication: Lube hinges and pivot points. Easiest to use liquid oil in a Zoom Spout bottle, a syringe, or something similar instead of aerosol. Much neater. • Service tailwheel: Per steps in “Landing Gear” section. Fuselage • Access: Remove all seats, all floor boards, the rear bulkhead, the left and right front kick panels, windshield side post (A-pillar) covers, and the side panels next to each front seat. Open zippers in headliner. Remove doors. • Clean: Vacuum out all areas under floors, and clean as required. • Fabric/Paint: Check general condition. • Stringers: Check condition and security. • Frame tubes: Inspect for damage or corrosion. • Drain holes: Check that drain holes in bottom of fuselage fabric are open, and no water is collecting. • Heater hose: Check SCAT tubing for rear heat. • Flap system: Check operation and condition of flap lever, release button, lock quadrant, cables, swages, pulleys, torque