ERCOUPE ANNUAL INSPECTION/WORK REPORT

Compiled by Ed Burkhead

Date: _________________________________                                                           

A/C reg #_________ MAKE_________ MODEL_________ S/N________ HOURS__________

ENGINE MAKE & MODEL_________________ ENG HRS___________ (TACH)(HOBBS)

DATE  PREV.  ANNUAL_________________ ENG HRS___________

OWNER: ___________________________________________________________________________

 
                ADDRESS:        __________________________________________________

                                __________________________________________________

                                __________________________________________________


 

INSPECTION PERFORMED BY __________________________________________________________

                ADDRESS:        __________________________________________________

                                __________________________________________________

                                __________________________________________________

                A & P NO:       __________________________________________________

Instructions:  Check [ ] if item is ok.  Add pertinent measurements or observations, including corrective actions.

[OK]            ITEM

[  ] A. D. NOTES

[  ] EQUIPMENT LIST

[  ] LOG BOOK ENTRIES

[  ] FORM 337s present reflecting all changes

[  ] WEIGHT & BALANCE

[  ] APPROVED FLIGHT MANUAL

[  ] AIRWORTHINESS CERTIFICATE (Does it match model as shown in log books?)

[  ] STATE REGISTRATION AND STICKER (if required)

[  ] RADIO LICENSE (for trips outside U.S.)



I.  Fuselage

1. Exterior

[  ] a. Skin/paint

[  ] b. Cleanliness

[  ] c. Check main spar for corrosion per ADs

[  ] d. Airspeed system tubing -- rubber connectors at wing seal gap

[  ] d. Windshield condition

[  ] f. Side & rear windows

[  ] g. Battery box drain tube extension (must extend 1/2" below fuselage per AD 47-20-08 ERCO.

2. Behind and under seat 

[  ] a. Check spars for corrosion per ADs

[  ] b. Push rods & ball joints-grease

[  ] c. Push rods test for rust (awl)

[  ] d. Aft quadrant - grease

[  ] e. Rudder & elevator cables

[  ] f. Check chafing blocks

[  ] g. Battery fluid levels

[  ] h. Battery compartment

3. Under instrument panel

[  ] a. Control wheel freeplay

[  ] b. Control wheel bushings

[  ] c. Control wheel U-joints

[  ] d. Control quad chain-lube

[  ] e. Control quad cables

[  ] f. Fuselage tank support

[  ] g. Trim lever - oil

[  ] h. Trim cable - oil

[  ] i. Inspect vacuum hoses for leaks

[  ] j. Install new filters in gyro instruments

4. Under floor boards

[  ] a. Lower quad bushings

[  ] b. Lower quad ball joints-grease

[  ] c. Check brake lines

[  ] d. Check fuel lines & primer

[  ] e. Check pitot/static tubes under floor and seat
[  ] f. Perform any recurrent corrosion inspection per AD

5. Other cockpit items

[  ] a. Fuel system gauges

[  ] b. Selector valves

[  ] c. Placards: fuel, baggage, etc.

[  ] d. Oil system pressure and temp gauges

[  ] e. Electrical system

        [  ] 1. Fuses/breakers

        [  ] 2. Switches

        [  ] 3. Bulbs/eyebrow lights

        [  ] 4. ELT battery

        [  ] 5. Wires & cables for wear and chaffing

[  ] f. Instruments

        [  ] 1. Range markings

        [  ] 2. Placards

        [  ] 3. Compass correction

        [  ] 4. Inspect compass bracket for cracks

[  ] g. Engine controls & placards

[  ] h. Safety belts and harness

[  ] i. Seats and upholstery

[  ] j. Floor boards and carpet

[  ] k. Fuselage tank finger screen

[  ] l. Microphone/speaker/headset condition, operation




 
x. Engine compartment

[  ] a. Brake master cylinder -- reservoir replenished with MilH-5606AM fluid [  ] ______ oz. required

[  ] b. Heating and ventilating



II. Wing and wing center section 

[  ] a. Fabric or metal condition/paint

[  ] b. Attachment fittings - feel for movement between wing attachment bolts and fittings when helper is lifting 

    and lowering wing-tip.  Visually check for cracks.

[  ] c. Aileron hinges - lubricate - LPS-3

[  ] d. Aileron pushrods - lubricate and test for corrosion (ice pick)

[  ] e. Check aileron free play < 5/16" per Service Memorandum 56 & 57

[  ] f. Bellcranks at wing gaps - lubricate

[  ] g. Tie down rings

[  ] h. Walkway, non-skid

[  ] i. Fuel system markings

[  ] j. Pitot/static tubes and connections

[  ] k. Electrical system to lights
[  ] l. Inspect aileron for sheared or soft rivets or corrosion
	especially at control rod connection

III. Empennage

[  ] a. Rudder & elev hinges-lubricate

[  ] b. Rudder attach fittings

[  ] c. Rudder freeplay ~1/8"

[  ] d. Rudder pushrods - oil - LPS-3

[  ] e. Elevator freeplay <= 3/16"

[  ] f. Trim tab setting range

         415-C: up ?  down ?

         415-D: up 0° down 60°

         415-E,G Forney F-1, F-1A, Alon A-2, A2-A: up 10°  down 36°

         M-10   up 7°-10° down 32°-36°

[  ] g. Trim tab cable - adjust to maximum speed position using cockpit control, at trim tab check that tab is against stop then remove connecter between tab and cable.  Pull tab to down position by hand and release, checking that spring can firmly push tab up against the stop (this is to prevent flutter in case the cable connector becomes loose in flight).  Reattach tab to cable while tab is against stop -- this should keep the same relationship between the control and the tab that existed before the check.

[  ] h. Elevator travel -- On rudder, lay out line at right angles to leading edge of rudder from point midway between attaching bolts of center hinge, and running to rudder trailing edge.  From intersection of this line and rudder trailing edge, measure up or downward to find travel of elevator.  Using reference hole, check elevator up-travel by pulling control wheel to full aft position as limited by stop on control wheel shaft.  Correct any error by adjustment of elevator control cables.  Tension on these control cables should be 160-190 pounds.  (Reference: Aircoupe Service Manual, Surface Controls and Rigging, Rigging of Elevator.  Elevator travel reference: Aircraft Specifications A-718 and A-787.)

         415-C: up 13° down 12° (3.25" up ±.25", 2.88" down ±.5")

         415-D: up  9° down 12° (2.2" up ±.25", 2.88" down ±.5")
    
         415-E,G Forney F-, F-1A,

         Alon A-2, A2-A: up 20° down 10° (4.9" up, 2.5" down)

         M-10: up 25°-24° down 32°-36°

[  ] i. Skin and paint 

[  ] j. Electrical system

[  ] k. Tie down ring





IV. Landing gear



1. Main gear

[  ] a. Brake lines

[  ] b. Pivot bearings

[  ] c. shock struts -- fill to inlet annually or more often (inlet is in back center of strut)

[  ] d. "springs"

[  ] 1. Doughnuts -- look for bulging, check tail height (should be 75") replace doughnuts if below 68"

[  ] 2. Belleville springs if present in place of doughnuts -- take apart every annual, clean and grease

[  ] e. Tire condition

[  ] f. Grease wheel bearings

[  ] g. Brake linings   Pad:    LH inner ________  RH inner _______

                  Thickness:    LH outer ________  RH outer _______

[  ] Hayes brakes: "when new, each of 6 blocks is 3/32 inch thick above retaining spring slot and may wear without loss of braking until retaining spring becomes exposed to drum.  When block has worn within approximately 1/36 inch of spring slot, all blocks should be replaced." Aircoupe Service Manual

[  ] Goodyear brakes: "Linings are .460 inches long when new.  When lining wears to approximately .323 inch (21/64 inch), there will be complete loss of braking; therefore, when either lining measures less than .375 inch (3/8) inch) both should be replaced.  Movable lining can be measured only by disassembly of brake unit; however, fixed lining may be measured by removal of wheel only and should provide sufficient indication of lining wear between disassembly periods.  At 25-hour checks, wear on fixed block may be determined with reasonable accuracy by inserting feeler gauge without removing wheel.  With brake "on," if feeler 7/64 inch thick can be inserted between brake assembly housing and disk, wheel should be removed for accurate check of fixed lining length." Aircoupe Service Manual

[  ] h. Check brake disk clips

[  ] i. Check brake hoses

[  ] j. Knee joint freeplay

[  ] k. Lube strut and arm attachments

[  ] l. Check attachment fittings



V.  Nose Gear

[  ] a. Tire condition

[  ] b. Grease wheel bearings

[  ] c. Steering collar & ball -- grease

[  ] d. Nutcracker -- lube

[  ] e. Lower bushing fit -- look for slop

[  ] f. Strut oil level

[  ] g. taxi spring height -- at least 2.75"

[  ] h. engine mount attachments 

[  ] i. control wheel tracking

[  ] j. Steering collar and bolt between steering pushrod and nose gear -- inspect for cracks (also make sure that old style socket ball fitting has been replaced with bolt (Skyport nose gear steering ball replacement kit)

                    

VI. Propeller

[  ] a. Blades, tips, leading edges, check for nicks

[  ] b. Attachment bolts and safteying

[  ] c. Tracking

[  ] d. Hub and backplate

[  ] e. Spinner attachment



VII. Engine

[  ] a. Fuel pump -- check screen according to AD 81-07-06 TELEDYNE CONTINENTAL MOTORS: Amendment 39-4071 and Continental Service Bulletin M81-8 dated March 9, 1981.  Fuel pump surge chamber.

[  ] b. Cleanliness/leaks

[  ] c. Compression     1=____/80  2=____/80  3=____/80  4=____/80

        comp last ann   1=____/80  2=____/80  3=____/80  4=____/80

[  ] d. Spark plugs

[  ] e. Cylinder walls

[  ] f. Breather tube 

[  ] g. Oil screen

[  ] h. Oil filter (if present) change

[  ] i. Change oil

[  ] j. Mag points, timing and impulse couplings

[  ] k. Clean out mixture valve -- Even if wired full rich, take apart and check occasionally.  Fibers from air filter can block holes in plate giving dangerously lean mixture.

[  ] l. Carburetor finger screen

[  ] m. Flush Carb float chamber

[  ] n. Gascolator screen & sump

[  ] o. Clean air cleaner (inspect for loose fibers that may be ingested by engine and mixture control)

[  ] p. Throttle control -- oil

[  ] q. Carb heat and mixture control -- check proper operation, oil

[  ] r. Check condition of fuel and air hoses

[  ] s. Baffles -- check condition

[  ] t. Exhaust stack condition

[  ] u. Heat muffler -- remove for inspection

[  ] v. Engine mounts -- check for sag, deterioration, damage

[  ] w. Cowling condition

[  ] x. Cowling support structure, fasteners

[  ] y. Chafing strips

[  ] z. Gascolator braces -- Must have two between gascolator and engine.  Ercoupe Service Bulletin #24A, mandatory, applies to all ERCO and Forney Coupes.  Must have old aluminum nipple replaced with brass nipple (AD-46-38-03).



VIII. Engine compartment electrical items                   

[  ] a. Starter brushes and switch

[  ] b. Generator brushes

[  ] c. Wire and cable runs

[  ] d. Ignition harness

[  ] e. Grounding strip from engine to engine mount



IX.  Avionics

[  ] a. Receivers

[  ] b. Transmitters

[  ] c. Transponder

[  ] d. Loran -- memory battery replacement due? _________

[  ] e. ELT -- battery replacement due?_________

[  ] f. Antennas and cables, condition, cables, and bonding to airframe

[  ] g. Bonding of engine and control surfaces to airframe

[  ] h. Shielding of ignition noise




 
X.  Flight test

[  ] a. Flight controls correct movement, throw

[  ] b. Position lights, landing lights

[  ] c. Mag drop

[  ] d. Carb heat

[  ] e. Oil pressure

[  ] f. Charge rate

[  ] g. Ground roll tracking

[  ] h. Idle -- observed rpm _______

[  ] i. Static rpm ______

[  ] j. Ambient temperature

[  ] k. Mixture operation

[  ] l. Cylinder head temperature  1.[  ]  2.[  ]  3.[  ]  4.[  ]

[  ] m. Exhaust gas temp  1.[  ]  2.[  ]  3.[  ]  4.[  ]

[  ] n. Fuel pressure, each pump

[  ] o. Trim range

[  ] p. Electrical system charging rate,  with lights

[  ] q. Brakes

[  ] r. Communication test, each radio

[  ] s. Loran operational test

[  ] t. Transponder check with traffic control

[  ] u. VOR test