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Aircraft 100-hour inspection checklist

Aircraft 100-hour inspection checklist

Use this checklist to perform thorough maintenance on key systems, log detailed findings, and assign follow-up tasks.

Use this template with Lumiform

  • Customize this template or build your own
  • Fill out templates via mobile app
  • Get reports and analyse your data
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Aircraft 100-hour inspection checklist

Use this checklist to perform thorough maintenance on key systems, log detailed findings, and assign follow-up tasks.

Use this template with Lumiform

  • Customize this template or build your own
  • Fill out templates via mobile app
  • Get reports and analyse your data
Prices start from ░░░ per month
Book a demo
Learn more
or Download template as PDF

This aircraft 100-hour inspection checklist helps aviation maintenance technicians complete thorough, FAA-compliant inspections for commercial aircraft. It covers essential inspection areas including general exterior condition, cabin and cockpit components, engine and propeller systems, and critical airframe elements.

As Air Cargo Week states, when an aircraft experiences mechanical issues requiring grounding, repair costs can range from $200,000 to over $2 million depending on engine type and damage severity. Using a comprehensive inspection checklist helps prevent potential problems from escalating into major repairs or safety hazards, ensuring your aircraft remains airworthy while minimizing expensive downtime.

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Preview of the template
Page 1
General Inspection
Perform general visual inspection of aircraft exterior
Check for signs of damage, corrosion or abnormal wear
Ensure all access panels and doors are properly secured
Ensure tires are properly inflated and in good condition
Check brake condition and operation
Cabin and Cockpit Inspection
Inspect seats, seatbelts and shoulder harnesses for condition and proper operation
Ensure all instruments, avionics and controls are functioning properly
Check emergency equipment (fire extinguisher, first aid kit, etc.) for presence and condition
Inspect cargo/baggage area and ensure proper restraint system is in place
Engine and Propeller Inspection
Inspect engine mounts, baffles and cowlings for condition
Check engine oil level and add as needed
Inspect propeller blades for cracks, nicks or other damage
Ensure propeller spinner is secure and in good condition
Airframe Inspection
Inspect wings, empennage, and flight control surfaces for condition
Check all flight control systems for proper operation
Inspect all exterior lights (navigation, landing, etc.) for proper operation
Ensure all placards and markings are legible and in place

Frequently asked questions

What happens if I miss something during a 100-hour inspection?

Missing critical items during an inspection could lead to mechanical failures, safety incidents, or regulatory violations. If you discover an oversight, immediately document the finding, address any safety concerns, and perform the required inspection. For serious oversights, consult with your local FSDO about proper documentation and any necessary reporting requirements.

How do I handle discrepancies found during a 100-hour inspection?

Document each discrepancy clearly in the inspection report with specific details about the condition found. Determine if the issue affects airworthiness or requires immediate attention. Repair critical items before returning the aircraft to service, and for non-critical issues, create a maintenance plan with appropriate timeframes for addressing them.

How can I customize this 100-hour inspection checklist for my specific aircraft?

Add aircraft-specific items based on your manufacturer’s maintenance manual. Include any recurring Airworthiness Directives or Service Bulletins applicable to your model. Adjust inspection intervals for components with special requirements. Consider adding sections for optional equipment or modifications unique to your aircraft to ensure complete coverage.

What should I do if I can’t complete the entire inspection in one session?

Document exactly which sections were completed and which remain outstanding. Secure the aircraft appropriately if partially disassembled. Create a clear plan for completing the remaining items. Remember that the aircraft cannot return to commercial service until the entire inspection is completed and properly signed off.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.