AC 43-209 

DATE: 10/16/03 

L-39 ALBATROSS MILITARY JET 

RECOMMENDED INSPECTION PROGRAM 

Initiated by: AFS-305
Subject: L-39 ALBATROSS MILITARY JET 

RECOMMENDED INSPECTION PROGRAM 

Date: 10/16/03 

Initiated By: AFS-305 

AC No: 43-209 

Change:

1. PURPOSE. This Advisory Circular (AC) provides a recommended inspection program for 

existing and new owners of L-39 Albatross aircraft operating under an Experimental Exhibition 

Special Airworthiness Certificate. While this AC provides one way of addressing the inspection 

and overhaul provisions found on the aircraft’s operating limitations, it may not be the only way 

of addressing the requirements for continued airworthiness of L-39 aircraft. This AC is not 

meant to supersede existing L-39 inspection programs. 

2. BACKGROUND. As of September 2003, there are approximately 220 L-39 aircraft 

registered in the United States. Because of the large number of L-39 aircraft operating in U.S. 

airspace, the owners of these aircraft requested the Federal Aviation Administration (FAA) 

standardize the scope and detail of the inspection and overhaul times of engines and other 

components of these aircraft. 

3. DESCRIPTION. This AC consists of an overview and three appendices: a recommended 

inspection program, an ejection seat/canopy inspection program, and a hard landing/off runway/ 

overstress inspection. The overview describes the aircraft, recommends using engine 

maintenance records to establish engine overhaul times for the AI-25TL engine, and provides 

other useful information. The inspection program contains airworthiness limitations (overhaul 

times for components other than the engine), maintenance preflight, engine run-up and systems 

checks, and 50, 100, and 400-hour inspections. The ejection seat/canopy inspection program

contains safety precautions and procedures. The recommended inspection program should be 

used with the aircraft maintenance manual and other manufacturer’s manuals when performing 

maintenance on the aircraft. 

4. OVERVIEW.

a. General. The L-39 Albatross is an all-metal, single-turbine engine, two place tandem

seat, subsonic military trainer aircraft. Aero Vodochody, located in the Czech Republic, 

manufactured the aircraft. The most popular model is the L-39C; approximately 3,000 of this 

model were manufactured. The L-39C model makes up the majority of the jet trainers imported 

into the United States and issued an Experimental Exhibition Special Airworthiness Certificate. 
AC 43-209 10/16/03 

b. L-39C Specifications (Abbreviated). 

Max speed at 16,400 ft......................407 knots (469 mph) 

Max speed at sea level .....................378 knots (435 mph) 

Length ..............................................39 ft., 8 inches 

Wing span ........................................31 ft. 

Height...............................................15 ft., 6 inches 

Wing area .........................................202 sq. ft. 

Flaps.................................................Double-slotted, Fowler-type 

Flaps takeoff.....................................25 degrees 

Flaps landing....................................44 degrees 

Empty weight...................................7,625 lbs. 

Max. takeoff weight.........................10,362 lbs. 

Max. landing weight ........................10,141 lbs. 

Normal takeoff weight .....................9,976 lbs. 

Empty aircraft weight C/G range..... 27.7 +/- .5% MAC (27.2 – 28.2% MAC) 

C/G range .........................................20.7 to 28% MAC 

Takeoff run....................................... 1,575 ft. 

Landing distance ..............................1,968 ft. 

Initial rate of climb .......................... 4,330 ft./min. 

Vmo knots..........................................491 knots 

Max load factor................................+8g, – 4g 

Mmo knots.........................................0.80 clean 

Range at 16,400 ft............................540 nautical miles 

Engine ..............................................3,792 lbs., Ukrainian Progress, Ivchenko AI-25TL. 

Twin shaft bypass turbofan engine. 

Bypass ratio 1.983. 

5. ENGINE OVERHAUL TIMES.

a. Determining Engine Overhaul Times. The AI-25TL engine has been in production for 

approximately 30 years. During the production run, the engine underwent many changes and 

modifications. These modifications increased the engine’s reliability and lengthened the time 

between overhauls. Since the majority of L-39 aircraft are older models imported into the United 

States from countries with different maintenance/inspection programs and recordkeeping 

requirements, it is difficult for the FAA to determine with a high degree of accuracy each individual 

engine’s overhaul time. Therefore, for the purpose of issuing an Experimental Exhibition Special

Airworthiness Certificate, the initial overhaul times for the AI-25TL engine will be based on the 

engine logbook and/or the engine manufacturer (Motor Sich) overhaul and life limits. While the 

factory recommended engine overhaul times for different engine serial numbers varies from 300 

hours to 1000 hours, the engine overhaul life limit for all engine serial numbers is 4000 hours total 

time in service.

NOTE: If an engine time cannot be documented (no logbook), or the engine 

has exceeded its overhaul limit or life limit, the aircraft in which the engine is 

installed will not be issued an experimental certificate. 

Page 2 Par 4 
10/16/03 AC 43-209 

b. Engine Storage Life. Engines which have exceeded storage life limits are 

susceptible to internal corrosion, deterioration of seals and coatings, and breakdown of 

engine preservation lubricants. If an engine has exceeded its recommended storage life 

limits, that engine’s fan, compressor, and turbine sections will be visually inspected for 

any sign of corrosion or other problems associated with long-term storage. If the engine 

is found to be airworthy it may be re-preserved in accordance with the manufacturer’s 

instructions and placed back in storage for the length of time specified in Table 1. This 

inspection and re-preservation must be documented in accordance with Title 14 of the 

Code of Federal Regulations (14 CFR) § 43.11 and signed off by a mechanic with at least 

a powerplant rating or an appropriately rated part 145 repair station. 

(1) At the end of the storage period, the engine must be reinspected. The engine, 

upon passing the inspection, can be re-preserved for an additional period of storage. The 

engine can be re-preserved a total of two times using this method. After the end of the 

second re-preservation inspection and storage, the engine must be either placed in service 

or overhauled. 

(2) If corrosion or other problems are found, they must be documented in the 

engine maintenance log. After the repairs are completed, the engine may be preserved in 

accordance with the manufacturer’s instructions and placed back in storage. 

Table 1. Storage Life Limits for Properly Preserved Engines

Moderate Climate

Conditions 

Tropical Climate 

Conditions

Engines in sheltered 

storage areas 

6 years 3 years 

Engines in 

unsheltered storage 

areas 

3 years 1 year 

NOTE: A sheltered storage area is an area that is protected from external 

environmental conditions (for example, a metal container or a room in which 

the temperature and humidity is controlled). 

c. Engine Overhaul Time Extension. The FAA understands that the original engine 

overhaul and time limits were set by the manufacturer to ensure safe engine operation under 

harsh military conditions. Presently, the FAA has no data to justify extension of the overhaul 

times on the AI-25TL engines. 

d. Information Warranting an Increase in Overhaul Times. If an owner seeks an 

increase in overhaul times, the FAA will consider any owner-supplied data/records/logbooks or 

other information from the engine manufacturer that documents specific modifications or service 

bulletins that were performed on the engine. The local FAA Flight Standards District Office (FSDO)

Par 5 Page 3 
AC 43-209 10/16/03 

Airworthiness aviation safety inspector (ASI) will determine if an increase in overhaul time is 

justified based on the above documents and revise the operating limitations for the aircraft. 

e. Privately-Owned L-39 Aircraft that Have Operated Under This Recommended 

Inspection Program for at Least Two Years. For these aircraft, the FAA will consider 

granting fleet-wide engine overhaul time extensions in increments of 50 hours each, not to 

exceed a total of 150 hours. Each of the three engine time increases will be based on the results 

of engine and accessories tear-down inspections and reports performed by an appropriately rated 

part 145 FAA Repair Station or by the engine manufacturer on five AI-25TL engines with 

identical overhaul times. If an increase in overhaul times for a particular series of engines is 

warranted, the FAA will revise appropriate portions of this AC to reflect the change in overhaul 

time. Once the revision to the AC is published, the owner can request that the local FSDO revise 

the aircraft’s engine life limits. 

6. OWNER INVOLVEMENT. The FAA’s desire is to work closely with L-39 owners to 

ensure safe operation of these high-performance aircraft. With a large number of L-39 aircraft, it 

would be impossible for the FAA to work with each owner on an individual basis. Therefore, 

the FAA is seeking to initially establish two L-39 safety working groups: a maintenance safety 

group and an operations safety group. Each FAA-recognized L-39 safety working group’s 

mission will be to promote safety within its area of expertise and to serve as an interface between 

the FAA and L-39 owners. Interested persons, please contact the Aircraft Maintenance Division, 

AFS-305 (telephone: (202) 267-3796). 

7. REVISIONS. The FAA ASI at the local FSDO may make minor changes to this inspection 

program based on installed equipment, environmental conditions, and operating conditions. 

Extensive revisions to this inspection program should be coordinated with AFS-305. 

8. COMMENTS INVITED. The FAA encourages public participation in updating this 

document. Please send comments, suggestions, or information about this AC to the following 

address: Aircraft Maintenance Division, AFS-305, Federal Aviation Administration, 800 

Independence Avenue, SW., Washington, DC 20591, or by FAX to 

(202) 267-5115. 

/s/ John M. Allen for 

James J. Ballough 

Director, Flight Standards Service 

Page 4 Par 5 
10/16/03 AC 43-209 

 Appendix 1 

APPENDIX 1. L-39 ALBATROSS RECOMMENDED INSPECTION PROGRAM 

L-39 ALBATROSS 

MANUFACTURED BY: AERO VODOCHODY, CZECH REPUBLIC 

SERIAL NUMBER: ____________________________________ 

REGISTRATION NUMBER: ____________________________ 

REGISTERED OWNER: _______________________________ 

ADDRESS: ___________________________________________ 

___________________________________________ 

FAA SIGNATURE: ____________________________________ 

FSDO ADDRESS: ____________________________________ 

 ____________________________________

 Page 1 
AC 43-209 10/16/03 

Appendix 1 

CONTENTS 

Page 

Appendix 1. L-39 Albatross Recommended Inspection Program......................................1 

Introduction: L-39 Inspection Program Responsibility .......................................................3 

Method of Revision .............................................................................................................5 

Log of Revisions..................................................................................................................6 

Safety Considerations..........................................................................................................7 

Airworthiness Limitations ...................................................................................................9 

Acceptable Oils, Greases, and Lubricants.........................................................................11 

Maintenance Preflight Inspection ......................................................................................12 

Engine Run-up and Systems Check...................................................................................18 

50-Hour/6-Month Periodic Inspection...............................................................................23 

100-Hour Inspection/Condition Inspection 

(Accomplished Every 12 Calendar-Months).....................................................................25 

400-Hour/48-Month Inspection .........................................................................................54 

Appendix 2. L-39 Ejection Seat/Canopy Inspection Program............................................1 

Safety Precautions When Servicing Ejection Seats.............................................................1 

Specified Work Operations 

(Work to be Performed Each 100-Hour/Condition Inspection)...........................................3 

L-39 Albatross Parachute/Pyro Log Sheet...........................................................................6 

Appendix 3. Hard Landing/Running Off Runway/Overstress Inspection Program........1 

Page 2 
10/16/03 AC 43-209 

 Appendix 1 

APPENDIX 1. L-39 ALBATROSS RECOMMENDED INSPECTION PROGRAM 

INTRODUCTION: 

L-39 INSPECTION PROGRAM RESPONSIBILITY 

The owner of N___________ Serial # ____________is responsible for scheduling and 

supervising the inspections required by this program while the aircraft is based 

at_______________ airport, city/county of ____________________, state 

of ___________________. 

If and when the aircraft is moved to another location, the owner will notify the local Federal 

Aviation Administration (FAA) Flight Standards District Office (FSDO) having jurisdiction over 

the area in which the aircraft is based, furnish it with a copy of the approved aircraft inspection 

program, and identify the person responsible for scheduling and performing the required 

inspections. 

The owner is responsible for having the inspection(s) performed as prescribed in the inspection 

program identified in the aircraft’s operating limitations and for keeping the records as required 

under Title 14 of the Code of Federal Regulations (14 CFR) § 91.417. 

 Page 3 
AC 43-209 10/16/03 

Appendix 1 

INTRODUCTION: 

L-39 INSPECTION PROGRAM RESPONSIBILITY (Continued) 

The owner shall ensure that all inspections are performed in accordance with the applicable L-39 

and other manufacturers’ maintenance manuals. In addition, the owner should ensure that all 

maintenance record entries are made in accordance with 14 CFR §§ 43.9 and 43.11 and retained 

in accordance with § 91.417. 

The following manuals should be readily available for referencing procedures and service 

instructions: 

1. L-39 Airframe and Engine Installation Manual. 

2. Engine Manual AI-25TL—Instructions for Operation. 

3. Engine Manual AI-25TL—Technical Description and Instructions for Operation. 

4. Electrical Equipment and Instruments—Technical Description and Instructions for 

Operation. 

5. Facilities for Work (systems manual(s))—Operations on the Aircraft Airframe, Including 

its Individual Systems. 

6. Armament and Rescue System—Ejection Seats. 

This inspection program includes the following items to be complied with at the specified 

intervals: 

1. Maintenance preflight: first flight of the day. 

2. Engine run-up and systems check: as required. 

3. Periodic inspection at 50 flight hours/6 months. 

4. Specified inspections at 100 flight hours/12 months. 

5. Specified inspections at 400 flight hours/48 months. 

6. Post inspection run-up and systems check: as required. 

7. Airworthiness limitations: as indicated. 

NOTE: The pressure gauges in the L-39C are calibrated in kg/cm2

. To find 

out the pressure in PSI, multiply the gauge reading by 14.2. For example, if 

the gauge reads 150 kg/cm2

, multiply 150 x 14.2 = 2130 PSI.

Page 4 
10/16/03 AC 43-209 

 Appendix 1 

METHOD OF REVISION 

Submit revisions of this manual to the local FSDO office for approval. 

Once approved by the FSDO, insert the revision into the approved aircraft inspection program. 

Enter revisions in the revision log, which lists the revision number, date, page, subject, and 

initials of person making the insertion.

Logbook Entries

Enter the following statement in the appropriate aircraft and/or engine logbook after each 

inspection: 

“I certify that this aircraft has been inspected on [insert date] in accordance with 

the scope and detail of the FAA-approved L-39 inspection program dated 

____________ for serial number __________, and found to be in a condition for 

safe operation.” 

Aircraft Total Time: __________ Inspection Type: 

Signature and A&P Certificate #: ___________________ Date: 

Enter the following statement in the appropriate aircraft and/or engine logbook if the aircraft was 

inspected and found not safe for flight: 

“I certify that this aircraft has been inspected on [insert date] in accordance with 

the scope and detail of the FAA-approved L-39 inspection program dated 

____________ for serial number __________, and found NOT in a condition for 

safe operation; a list of unsafe items has been provided to the owner on this 

date____________.” 

Aircraft Total Time: __________ Inspection Type: 

Signature and A&P Certificate #: ___________________ Date: 

24 Calendar-Month Items 

Conduct a pitot/static system and transponder check in accordance with part 43, appendices E 

and F, every 24 calendar-months, or after system maintenance if the aircraft is operated under 

instrument flight rules. 

 Page 5 
AC 43-209 10/16/03 

Appendix 1 

LOG OF REVISIONS 

REVISION 

NUMBER 

DATE REMOVED

PAGE # 

INSERTED 

PAGE # 

SUBJECT INITIALS

Page 6 
10/16/03 AC 43-209 

 Appendix 1 

SAFETY CONSIDERATIONS 

READ BEFORE STARTING ANY INSPECTION 

1. Engine Run-Up and Systems Checks. These checks will be performed before the 

inspection. All run-up sheets will be attached to the inspection checklist and become part of the 

aircraft’s maintenance records. 

2. Ground the Aircraft. Static electricity could cause a fire or explosion, set off 

pyrocartridges, or result in any combination of the above. 

CAUTION: Ground the aircraft, ensure all electrical tools are grounded, 

and use industry-approved explosion-proof flashlights or other lighting 

sources. 

3. Ejection Seats (if Installed). Confirm the status of the ejection seats and canopy in both 

the front and aft cockpit as soon as the engine is shut down. Install all safety pins in the firing 

mechanisms of pyrocartridges. After the pilot has exited the aircraft, close and lock the 

canopies. Confirm warning placards are legible and in good condition. Do not attempt to 

remove cartridges from firing chambers or remove either seat from the aircraft without first 

consulting a technician trained and experienced in removing those seats. Consult the armament 

and rescue system manual. (Instructions for seat inspection are in Appendix 2, L-39 Ejection 

Seat/Canopy Inspection Program.) 

4. Radioactive Components. 

a. The transmitter of the ice accretion system on the left underside of the nose must have 

its special cover installed when the aircraft is on the ground. It can be removed by the pilot 

when entering the cockpit. 

b. The engine ignition system (high voltage energy source) contains built-in radioisotopes. 

c. Do not dismantle either of the above systems. If any part of the transmitter of the ice 

accretion system or the high voltage energy source is damaged, it must be specially wrapped and 

disposed of following Environmental Protection Agency (EPA) guidelines. 

5. Fire Risk. Do not allow oil, fuel, kerosene, or any cleaning fluid to come in contact with 

the oxygen installation. This could cause an explosion or fire. 

6. Gear Positions. Before moving or working on the aircraft, confirm the front cockpit 

landing gear control is in the “down” position and the landing gear control in the aft cockpit is in 

the “neutral” position. 

SAFETY CONSIDERATIONS (Continued) 

 Page 7 
AC 43-209 10/16/03 

Appendix 1 

7. Ensure Access. Position controls for access during inspections:

• Landing gear doors open 

• Flaps extended 

• Ram air turbine extended 

• Parking brakes applied and wear indicators checked 

8. Hydraulic Pressure. Reduce hydraulic pressure to 0 (zero) before working in or near the 

gear wells or dive brakes, or before working on any hydraulic components. 

Page 8 
10/16/03 AC 43-209 

 Appendix 1 

AIRWORTHINESS LIMITATIONS 

This inspection program specifies that the following components be replaced or overhauled in 

accordance with the manufacturer’s data at the specified intervals: 

ENGINE (S/N_______________) 4000 HOURS—REPLACE 

(MODEL_______________) 

ENGINE (TOTAL TIME____________) XXX HOURS—OVERHAUL (to be 

determined by engine S/N and logbook 

documentation) 

FUEL REGULATOR ENGINE OVERHAUL 

FUEL PUMP ENGINE OVERHAUL 

OIL TANK ENGINE OVERHAUL 

OIL UNIT ENGINE OVERHAUL 

AIR SEPARATOR ENGINE OVERHAUL 

FUEL OIL UNIT ENGINE OVERHAUL 

START-IN TURBINE ENGINE OVERHAUL 

IGNITION ENGINE OVERHAUL 

SPARK PLUGS ENGINE OVERHAUL 

ELECTRO MECHANISM ENGINE OVERHAUL 

STARTER ENGINE OVERHAUL 

SAPPHIRE GAS GENERATOR 3000 STARTS—OVERHAUL 

FUEL TANKS 10 YEARS—REPLACE 

LANDING GEAR (NOSE) 3000 LANDINGS/12 YEARS—OVERHAUL 

LANDING GEAR (MAIN) 3000 LANDINGS/12 YEARS—OVERHAUL 

BRAKES (LEFT/RIGHT) ON CONDITION—REPLACE 

 Page 9 
AC 43-209 10/16/03 

Appendix 1 

AIRWORTHINESS LIMITATIONS (Continued) 

ROCKET ENGINE 8 YEARS—REPLACE 

PARACHUTE 5 YEARS—REPLACE 

PARACHUTE STABILIZATION SYSTEM 5 YEARS—REPLACE 

CARTRIDGES (2 EACH) PER MANUFACTURER’S INSTRUCTIONS 

BATTERY ON CONDITION 

TURBO-COOLER 1000 HOURS—OVERHAUL 

3000 HOURS—REPLACE 

FRONT WINDSHIELD SEALING HOSES IF HANGARED FULL-TIME, 

ON CONDITION 

IF NOT, 8 YEARS—REPLACE 

FRONT CANOPY SEALING HOSES IF HANGARED FULL-TIME, 

ON CONDITION 

IF NOT, 8 YEARS—REPLACE 

REAR CANOPY IF HANGARED FULL-TIME, 

SEALING HOSES ON CONDITION 

IF NOT, 8 YEARS—REPLACE 

HYDRAULIC PUMP 1200 HOURS—OVERHAUL 

HYDRAULIC ACCUMULATOR 1500 HOURS/8 YEARS—OVERHAUL 

NITROGEN BOTTLE PER MANUFACTURER’S INSTRUCTIONS 

OXYGEN BOTTLE PER MANUFACTURER’S INSTRUCTIONS 

FIRE BOTTLES PER MANUFACTURER’S INSTRUCTIONS 

TEMPERATURE REGULATOR 6000 HOURS—OVERHAUL 

RT-9-2 SERIES 8000 HOURS—REPLACE 

NOTE: Replacement of pressure bottles will be accomplished in accordance 

with the manufacturer’s recommendations and applicable federal regulations. 

Page 10 
10/16/03 AC 43-209 

 Appendix 1 

ACCEPTABLE OILS, GREASES, AND LUBRICANTS 

FUEL....................................................................JET A 

TURBOJET ENGINE OIL..................................ROYCO 481 MIL SPEC L6081C 

SAPPHIRE ENGINE OIL ...................................ROYCO 481 MIL SPEC L6081C 

TURBO-COOLER...............................................MOBIL JET OIL II—SYNTHETIC OIL 

AIR STARTER....................................................MOBIL JET OIL II—SYNTHETIC OIL 

GREASE: 

WHEEL BEARINGS..................................AEROSHELL #22 

FLAP TRACKS..........................................LUBRIPLATE 630 

 AEROSHELL #5 

GENERAL APPLICATIONS ....................LUBRIPLATE 630 

 AEROSHELL #22 

 AEROSHELL #17 

HYDRAULIC FLUID .........................................MIL 5606 

NOTE: Control hinges, control rod end bearings, and bellcranks are 

packed with grease (Lubriplate 630, Aeroshell #22, or similar grease) at 

assembly. During inspections it is generally not necessary to disassemble 

each control rod end to grease. Use of LPS-2 will displace moisture and 

maintain a film of lubrication.

MAINTENANCE PREFLIGHT INSPECTION 

 Page 11 
AC 43-209 10/16/03 

Appendix 1 

1. Front Fuselage: 

a. Skin for damage. ______________ 

b. Nitrogen pressure per manual requirements. ______________ 

c. Both nose side doors opened, inspected, closed, and secure. ______________ 

d. Protective cover on ice indicator pickup positioned correctly. ______________ 

2. Nose Undercarriage: 

a. Tire: 

 Condition ______________ 

Inflation (70 PSI) ______________ 

b. Strut extension. ______________ 

c. Shimmy damper for security and leaks. ______________ 

3. Right Intake: 

Check for general condition: 

 Inside ______________ 

 Outside ______________ 

4. Right Undercarriage: 

a. Tire: 

 Condition ______________ 

Inflation (85 PSI) ______________ 

b. Strut extension. ______________ 

c. Brakes—check wear indicator when brakes are applied. ______________ 

d. Check for fuel or hydraulic fluid in landing gear area. ______________ 

e. Check wheel-well area for security of hydraulic and fuel lines. 

f. Take fuel sample from No. 5 fuel tank and check for contamination. ______________ 

g. Check landing gear up-locks for condition. ______________ 

h. Check door up-locks for condition. ______________ 

i. Inner gear door: 

 General condition ______________ 

 Hinges ______________ 

Page 12 
10/16/03 AC 43-209 

 Appendix 1 

MAINTENANCE PREFLIGHT INSPECTION (Continued) 

5. Right Wing: 

a. Wing fairings for condition. ______________ 

b. Flaps: 

 Condition ______________ 

Guide rails for cleanliness ______________ 

c. Aileron: 

 Condition ______________ 

 Hinges ______________ 

 Security ______________ 

 Trim tab ______________ 

d. Wing-tip tank: 

 Condition ______________ 

 Cap secure ______________ 

Drain fuel specimen ______________ 

e. Check for fuel or hydraulic fluid leaks. ______________ 

f. All inspection doors closed. ______________ 

g. Skin condition: 

 Top ______________ 

 Bottom ______________ 

6. Right Fuselage: 

a. Open inspection door to engine compartment: 

Check for fuel or hydraulic fluid leaks ______________ 

Check for security of engine controls ______________ 

Check oil quantity ______________ 

CAUTION: If oil quantity is exceptionally low, oil may have bypassed into 

the lower accessory case. In this case, the engine should be cold-run. Recheck the oil and add if necessary. Should this condition repeat itself when 

the aircraft is inactive for a period of time, it will be necessary to clean the 

check valve at the oil pump, as referenced in the AI-25TL Engine Manual, 

chapter 6.2, step 11. 

b. Skin: 

 Condition ______________ 

Inspection doors secure ______________ 

 Page 13 
AC 43-209 10/16/03 

Appendix 1 

MAINTENANCE PREFLIGHT INSPECTION (Continued) 

7. Tail Section: 

a. Skin: 

 Condition ______________ 

5 assembly covers (tail cone to fuselage) secure ______________ 

b. Elevator: 

 General condition ______________ 

 Hinges ______________ 

 Trim tabs ______________ 

c. Rudder: 

 General condition ______________ 

 Hinges ______________ 

 Trim tab ______________ 

d. Tail fairings: 

 Condition ______________ 

 Security ______________ 

8. Exhaust Pipe (use an industry-approved explosion-proof flashlight): 

a. General condition. ______________ 

b. Security. ______________ 

c. Turbine blade condition for turbine staves, and mixing chamber 

cone for cracks in welding seam. Check for fuel and oil residue, 

which indicates worn-out bearings, and metal spray on exhaust 

pipe walls, which indicates melted high-pressure turbine parts. ______________ 

9. Left Fuselage (open engine inspection door to engine compartment): 

a. Check for fuel or hydraulic fluid leaks. ______________ 

b. Check oil level in the Sapphire tank. 

(MAX = 20 mm below MAX line) ______________ 

c. Check compressor blades of Sapphire. ______________ 

d. Check for any loose objects in engine compartment. ______________ 

e. Rotate main engine using special wrench. ______________ 

f. Close inspection door and secure. ______________ 

g. Check level of hydraulic fluid and replenish if necessary. ______________ 

h. Inspect oil chip magnetic plug. ______________ 

Page 14 
10/16/03 AC 43-209 

 Appendix 1 

MAINTENANCE PREFLIGHT INSPECTION (Continued) 

CAUTION: Before opening the hydraulic system, check pressure in main 

and emergency hydraulic system before bleeding head pressure from 

hydraulic tank. Be sure to close hydraulic valve (HV-5) after bleeding air. If 

you do not close the valve, you will lose your canopy sealing system in flight 

and have low hydraulic pressure in the main system. 

10. Left Wing: 

a. Wing fairings for condition. ______________ 

b. Flaps: 

 Condition ______________ 

Guide rails for cleanliness ______________ 

c. Aileron: 

 Condition ______________ 

 Hinges ______________ 

 Security ______________ 

 Trim tab ______________ 

d. Wing-tip tank: 

 Condition ______________ 

 Cap secure ______________ 

Drain fuel specimen ______________ 

e. Check for fuel or hydraulic fluid leaks. ______________ 

f. All inspection doors closed. ______________ 

g. Skin condition: 

 Top ______________ 

 Bottom ______________ 

11. Left Undercarriage: 

a. Tire: 

 Condition ______________ 

Inflation (85 PSI) ______________ 

b. Strut extension. ______________ 

c. Brakes—check wear indicator when brakes are applied. ______________ 

d. Check for fuel or hydraulic fluid in landing gear area. ______________ 

e. Check wheel-well area for security of hydraulic and fuel lines. ______________ 

 Page 15 
AC 43-209 10/16/03 

Appendix 1 

MAINTENANCE PREFLIGHT INSPECTION (Continued) 

f. Check landing gear up-locks for condition. ______________ 

g. Check door up-locks for condition. ______________ 

h. Inner gear door: 

 General condition ______________ 

 Hinges ______________ 

12. Fuselage Bottom Section: 

a. General condition. ______________ 

b. Check for oil, fuel, or hydraulic leaks. ______________ 

13. Left Intake: 

Check for general condition: 

 Inside ______________ 

 Outside ______________ 

14. Upper Fuselage: 

a. Skin condition. ______________ 

b. Inspection covers closed and secured. ______________ 

c. Check fuel quantity visually and record amount indicated 

on the gauges. Compare these figures with the fuel tank readings 

during run-up/taxi. ______________ 

15. Cockpits: 

a. Rear: 

 Plexiglass ______________ 

Hinges aligned properly ______________ 

Hinged retainer operates properly to hold canopy open ______________ 

Hinged retainer releases normally to close canopy ______________ 

b. If ejection seat is armed:

Check all pins in place ______________ 

Check 4 cartridges’ safety pins in place ______________ 

Check canopy emergency handle safetied ______________ 

Check for any loose articles in the cockpit ______________ 

Page 16 
10/16/03 AC 43-209 

 Appendix 1 

MAINTENANCE PREFLIGHT INSPECTION (Continued) 

c. Front: 

 Plexiglass ______________ 

Hinges aligned properly ______________ 

Hinged retainer operates properly to hold canopy open ______________ 

Hinged retainer releases normally to close canopy ______________ 

d. If ejection seat is armed:

Check all pins in place ______________ 

Check 4 cartridges’ safety pins in place ______________ 

Check canopy emergency handle safetied ______________ 

Check for any loose articles in the cockpit ______________ 

 Page 17 
AC 43-209 10/16/03 

Appendix 1 

ENGINE RUN-UP AND SYSTEMS CHECK 

NOTE: Engine run-up must be performed in accordance with 

chapter 5 of the AI-25TL maintenance manual. 

AFTER STARTING ENGINE: 

1. Sapphire start normal (min. running time: 30 seconds before engine start). ______________ 

2. Engine start normal. ______________ 

3. Maximum temp. during start was __________oC. ______________ 

4. Engine idle—remain at idle for 1-minute warm-up. 

a. N1: 54.5 – 57.5%. ______________ 

b. Oil pressure: 2 – 4.5 kg/cm2

. ______________

c. Exhaust Gas Temperature (EGT) 

(max. 600o C) actual _________oC. ______________ 

d. Hydraulic pressure: 150 + 10/-15 kg/cm2

. ______________

e. Check emergency hydraulic pressure is equal to main hydraulic 

pressure. If not, move hydraulic system lever from forward position 

to interconnection position until pressure equalizes. ______________ 

f. Brake pressure: 33 +3/-3 kg/cm2. ______________

CAUTION: Do not press brake lever if there is less 

than 50 kg/cm2 pressure in the system—damage to the 

brake system may result. 

g. Brake pressure emergency: 32 +8/-3 kg/cm2

. ______________

h. Generator voltage: 27 – 29 V (checked at N1 70%). ______________ 

i. Ammeter shows charge (main and emergency generators). ______________ 

j. Check brake pressure. ______________ 

k. Close canopy and lock. “Canopy Unlocked” light will go off. ______________ 

l. Move air condition-pressurize lever forward to stop-dog. 

“Air Condition Off ” light will go out. ______________ 

m. Check pressurization by reduction in cockpit noise level. 

Pressurization will read 0.021 kg/cm2

. ______________

n. Check flight controls for freedom of movement and full travel. ______________ 

o. Set elevator trim. ______________ 

NOTE: Trim indicator follows trim setting. 

Page 18 
10/16/03 AC 43-209 

 Appendix 1 

ENGINE RUN-UP AND SYSTEMS CHECK (Continued) 

5. Check operation of air bypass valve (stage III). Advance throttles 

slowly and monitor RPM. N2 RPM needle will jump to an increase 

of 3 – 4% when N1 is between 74 – 78% as the air bypass valve 

closes. ______________

6. Advance throttle to N1 85% and warm up for 1 min. minimum.

Check flap system: 

a. Extend to takeoff position. ______________ 

b. Extend to landing position. ______________ 

c. Retract to takeoff position. ______________ 

d. Retract to “up” position. ______________ 

e. Indicator lights operational. ______________ 

f. Time of extension and retraction: 

Flight—takeoff 1 – 3 sec. ______________ 

Flight—landing 4 – 7 sec. ______________ 

7. Check operation of air bypass valve (stage V). Advance throttles 

slowly and monitor RPM. N2 RPM needle will jump 1 – 2% when 

N1 is between 86 – 90% as the air bypass valve closes. ______________ 

8. Check engine oil temperature: 5o C minimum. If not, increase the 

throttle to N1 93% and continue warm-up until 5o C is attained. ______________ 

9. Advance throttle to N1 85%. 

a. EGT max. 590o C. ______________ 

b. Increase N1 to 99.6% +/- 1% according to standard atmosphere. ______________ 

c. Engine vibration meter should be between the yellow lines. ______________ 

d. Check fuel pump operation. 

Turn boost pump off ______________ 

NOTE: “Don’t Start” light comes on and engine parameters 

remain the same. 

Turn fuel boost pump on ______________ 

CAUTION: If the Lund 1374-8 thermocouple is installed 

instead of the T-99 (connected with the change of the RT-12-9 

regulator’s setting), the maximum EGT is 610o C. 

ENGINE RUN-UP AND SYSTEMS CHECK (Continued) 

 Page 19 
AC 43-209 10/16/03 

Appendix 1 

10. Advance throttle to nominal. 

a. EGT max.: 605o C. ______________ 

b. N1: 103.2 +/- 1%. ______________ 

c. Engine vibration meter should be between the yellow lines. ______________ 

d. Generator voltage: 27 – 29 volts. ______________ 

e. Check auto mode of cockpit temperature controller. ______________ 

f. Check auto mode of air shower temperature controller. ______________ 

11. Advance throttle to forward stop: 

a. MAX throttle should not reach forward stop. Throttle is limited 

by MAX stop on FCU-4000. ______________ 

b. Engine vibration meter should be between the yellow lines. ______________ 

c. N1 : 106.8 +/- 1% according to standard atmosphere. ______________ 

d. EGT max: 660o C. ______________ 

e. Oil pressure: 3 – 4.5 kg/cm2

. ______________

f. Oil temperature: +5 to +90o C. ______________

g. Max. fuel pressure: 65 kg/cm2

. ______________

NOTE: Fuel pressure at this reading will be used for the 

acceleration check.

12. Reduce throttle slowly. 

a. Check that air bypass valve (stage III) opens at N1 89 – 86%. ______________ 

b. The N1 needle will indicate a sudden decrease of 1 – 2% 

as the valve opens. ______________ 

c. Reduce the throttle further and note the N2 RPM needle will 

indicate a sudden decrease from 77% to 74%, signifying that 

the air bypass valve of stage V has opened. ______________ 

13. Engine acceleration check (note: do not exceed engine operating 

 parameters). 

a. Record the fuel pressure after 30 sec. at idle. ______________ 

b. Advance the throttle smoothly from idle to full throttle 

within 1 – 2 sec. Note at what time the fuel pressure reaches 

MAX pressure minus 10%. This should be 9 – 12 seconds. _____________ 

c. After 15 sec. at full throttle, record the time and smoothly reduce 

the throttle to idle within 1 – 2 sec. ______________ 

ENGINE RUN-UP AND SYSTEMS CHECK (Continued) 

Page 20 
10/16/03 AC 43-209 

 Appendix 1 

d. N1 at idle should stabilize within 45 sec. after rapid 

deceleration. Fuel pressure should go down to idle value 

within 5 seconds. ______________ 

NOTE: If N1 drops below 54.5% during throttling down, cut the 

engine off by displacing the throttle handle to the “Stop” position. 

14. Check deicing system at N1 85% NOMINAL for 30 seconds only. 

a. Switch deicing switch to “on” position. Engine temp. will rise 

20-30 degrees max. “Deicing On” light will light 30 seconds later. ______________ 

b. Switch deicing off. Temp. will decrease and deicing light will 

go off. ______________ 

NOTE: Engine run-ups at temperatures below +5o C require 

the deicing system to be on after the engine is on idle for the 

whole period of the run-up. 

15. Check engine overheat protective system. 

a. Turn generator off and close cockpit air conditioning. Both 

generator light and “Air Conditioner Off” light will come on. ______________ 

b. Set throttle to N1 70%. ______________ 

c. Pt-12-9 switch to “Check I” position. “700o C” light will turn on 

and RPM should start diminishing. As soon as N1 diminishes 

and starts dropping by 2 – 3%, switch PT-12-9 to neutral position. 

“700o C” light should go out and N1 should return to 70%. ______________ 

d. Turn generator on. ______________ 

16. Low-speed taxi check. 

a. Brake operation. ______________ 

b. Differential braking. ______________ 

c. Emergency braking. ______________ 

17. Emergency fuel system check. 

a. Turn generator, cockpit air conditioning, and deice system off. ______________ 

b. Test with no load on the hydraulic system. ______________ 

c. Adjust N1 to 70%. ______________ 

d. Emergency fuel switch on. ______________ 

e. Emergency fuel delivery warning light on. ______________ 

NOTE: High pressure compressor RPM may change when emergency 

fuel is turned on. 

 Page 21 
AC 43-209 10/16/03 

Appendix 1 

ENGINE RUN-UP AND SYSTEMS CHECK (Continued) 

f. Advance throttle smoothly and note the 3 – 4% jump in N1.

Check the RPM chart on page 251, figure 41 of the 

Airframe and Engine Manual. A 2% variation is allowed. The air 

bypass valves of stage III and stage V operate simultaneously 

when the emergency fuel system is on. ______________ 

NOTE: Do not allow the RPM to decrease below 56% N1

when using the emergency fuel system.

CAUTION: Do not switch from emergency fuel system 

to the main system when the engine is running.

18. Shut the engine down by closing the throttle to the stop position. ______________ 

19. After moving the throttle to the stop position, switch from emergency 

fuel system to main fuel system. ______________ 

20. Note time of engine run-down (10 seconds minimum). ______________ 

Page 22 
10/16/03 AC 43-209 

 Appendix 1 

50-HOUR/6-MONTH PERIODIC INSPECTION 

NOTE: This preventive maintenance inspection can be performed by a rated 

pilot who is properly trained to perform these tasks in accordance with the 

appropriate maintenance manual. The inspection is signed off in accordance 

with the aircraft’s operating limitations. 

1. Lubricate landing gear: 

 Left _____________ 

 Right _____________ 

 Nose _____________ 

2. Lubricate flaps: 

 Left _____________ 

 Right _____________ 

3. Lubricate rudder pedals: 

 Front _____________ 

 Rear _____________ 

4. Lubricate controls and trim tabs: 

a. Aileron and trim tabs: 

 Left _____________ 

 Right _____________ 

b. Elevators and trim tabs: 

 Left _____________ 

 Right _____________ 

c. Rudder and trim tabs. _____________ 

5. Clean and inspect 3 hydraulic filters per manual. If non-metallic filter 

elements are installed, replace them. _____________ 

6. Replenish hydraulic fluid in the tank. _____________ 

7. Check and service nitrogen pressure in accumulators: 

 Main _____________ 

 Emergency _____________ 

8. Replenish the oil in the turbo cooler. _____________ 

50-HOUR/6-MONTH PERIODIC INSPECTION (Continued) 

 Page 23 
AC 43-209 10/16/03 

Appendix 1 

9. Check and clean fuel filter of fuel/oil heat exchanger. (Bleed air out of

system prior to run-up.) ______________ 

10. Obtain engine oil sample and send to laboratory for analysis. ______________ 

11. Inspect stator and LPC blades of stage I visually through the air 

intakes for visible damage. ______________ 

12. Inspect stator and HPC blades of stage I with borescope. 

(See Engine Manual part 2, § 5.11.) Borescope: Make: ______________ 

For parameters of blade damage allowed, Model: ______________ 

refer to Engine Manual part 2, appendix 2. S/N: ______________ 

NOTE: For parameters of blade damage allowed, refer to 

Engine Manual part 2, appendix 2. 

13. Conduct engine test run and systems and taxi checks as given in 

Engine Manual part 2, § 5.1. Use an engine run-up check sheet 

and insert completed run-up sheet in aircraft maintenance records. ______________ 

14. Make entries in the appropriate logbooks. ______________

Page 24 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

(ACCOMPLISHED EVERY 12 CALENDAR-MONTHS) 

This inspection is divided into 8 zones and operational checks with a double sign-off. Ideally, 

the inspection task is performed by one mechanic and followed by another mechanic inspecting 

the work performed. 

ZONE 1 FUSELAGE — NOSE SECTION 

ZONE 2 FUSELAGE — COCKPIT SECTION 

ZONE 3 FUSELAGE — FUEL TANK AND ENGINE SECTION 

ZONE 4 FUSELAGE — TAIL CONE SECTION 

ZONE 5 RIGHT WING AND CENTER SECTION 

ZONE 6 LEFT WING AND CENTER SECTION 

ZONE 7 WHEELS AND BRAKES 

ZONE 8 OPERATIONAL CHECKS 

 Page 25 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 1: FUSELAGE—NOSE SECTION

1. Open and inspect nose cowling doors: 

a. General condition. _______________ 

b. Hinges for security and condition. _______________ 

c. Lubricate hinges. _______________ 

d. Security of latches. _______________ 

2. Inspect batteries for: 

a. Security. _______________ 

b. Electrolyte level, if applicable. _______________ 

c. Batteries charged to 24V. _______________ 

d. Vent system condition, if applicable. _______________ 

3. Inspect electric wire bundles and junctions for: 

a. General condition. _______________ 

b. Security. _______________ 

4. Inspect electrical systems and radios for: 

a. General condition. _______________ 

b. Security of attachments. _______________ 

5. Inspect high-pressure bottles for attachment and security of lines: 

a. Nitrogen. _______________ 

b. Oxygen. _______________ 

6. Inspect ice accretion sensor for: 

a. Security. _______________ 

b. Secure fit of cover. _______________ 

WARNING: Cover must be on this sensor when the aircraft 

is parked. This sensor is radioactive. Refer to Appendix 1, 

page 7, Safety Considerations.

Page 26 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 1: FUSELAGE—NOSE SECTION (Continued) 

7. Open nose gear door for inspection: 

a. Nose gear actuator for security and leaks. _______________ 

b. Nose gear door actuator for security and leaks. _______________ 

c. All hydraulic plumbing for security and leaks. _______________ 

d. Nose gear oleo for extension (2 – 3") and for leaks. _______________ 

e. Shimmy damper for condition and attachment. _______________ 

f. Service shimmy damper. _______________ 

g. Scissors for condition and bushing wear. _______________ 

h. Trunion for attachment and bushing wear. _______________ 

i. Tire for condition and inflation. _______________ 

j. Lubricate all grease fittings on scissors and trunion. _______________ 

8. Confirm that all placards are in place for: 

a. Nitrogen service. _______________ 

b. Oxygen service. _______________ 

c. WARNING—radioactive sensor. _______________ 

9. Inspect skin for condition and loose rivets. _______________ 

10. Close and secure all access doors and ensure radioactive cover 

is in place. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 1 THROUGH 10. _______________ 

 Page 27 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 2: FUSELAGE—COCKPIT SECTION

(Covers area from nose section to leading edge of wings.) 

11. Inspect skin for: 

a. General condition. _______________ 

b. Loose rivets. _______________ 

c. Corrosion. _______________ 

12. Remove inspection panels and open all inspection doors to facilitate 

inspection. Inspect panels and doors for: 

a. General condition and corrosion. _______________ 

b. Security of hinges and attachments. _______________ 

c. Security of latching mechanisms. _______________ 

d. Lubrication—lubricate as required. _______________ 

13. Inspect control rods in belly for: 

a. Security and safetying: 

 Rudder _______________ 

 Aileron _______________ 

 Elevator _______________ 

b. General condition and check for corrosion: 

 Rudder _______________ 

 Aileron _______________ 

 Elevator _______________ 

c. Move controls full travel by control stick and rudder pedals. 

(1) Observe control rod and bellcrank movement. 

(2) Check for chafing and freedom of movement. 

(3) Inspect bellcranks. Lubricate pivot points and control rod 

bearings: 

 Rudder _______________ 

 Aileron _______________ 

 Elevator _______________ 

Page 28 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 2: FUSELAGE—COCKPIT SECTION (Continued) 

14. Inspect electrical equipment and wiring in the belly for: 

a. General condition. _______________ 

b. Security of attachment. _______________ 

c. Cannon plug security and sealant. _______________ 

15. Inspect plumbing in belly for: 

a. General condition. _______________ 

b. Leaks. _______________ 

c. Security of attachment. _______________ 

16. Inspect hydraulic accumulators for: 

a. General condition. _______________ 

b. Security. _______________ 

c. Service (735 PSI nitrogen +/- 5 PSI). _______________ 

17. Cockpit inspection. 

CAUTION: Make sure all safety pins are installed in 

seats and canopy ejection firing mechanisms. Follow

instructions in Appendix 2, page 3, if seats are to be 

removed. 

a. Inspect canopy for general condition: 

 Front _______________ 

 Rear _______________ 

b. Fit in hinges: 

 Front _______________ 

 Rear _______________ 

c. Proper latching: 

 Front _______________ 

 Rear _______________ 

d. “Canopy Unlocked” warning when canopy is open 

or not fully locked: 

 Front _______________ 

 Rear _______________ 

 Page 29 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 2: FUSELAGE—COCKPIT SECTION (Continued) 

e. General condition of canopy seal: 

 Front _______________ 

 Rear _______________ 

f. Seal inflation. 

(1) Close canopy and inflate seal. 

(2) Check for proper operation and leaks: 

 Front _______________ 

 Rear _______________ 

g. Condition of canopy plexiglass: 

 Front _______________ 

 Rear _______________ 

18. Inspect windshield for: 

a. General condition. _______________ 

b. Security—latch bolts in place and safety covers installed. _______________ 

c. Condition of plexiglass windshield. _______________ 

19. Check that cockpit labeling is in English: 

a. Switches (front): 

 Left Deck _______________ 

 Panel _______________ 

 Right Deck _______________ 

b. Switches (rear): 

 Left Deck _______________ 

 Panel _______________ 

 Right Deck _______________ 

c. Handles and controls (front): 

 Left Deck _______________ 

 Panel _______________ 

 Right Deck _______________ 

Page 30 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 2: FUSELAGE—COCKPIT SECTION (Continued)

d. Handles and controls (rear): 

 Left Deck _______________ 

 Panel _______________ 

 Right Deck _______________ 

20. Inspect instruments and gauges for proper labeling and general 

condition. _______________

NOTE: Operational check is included in pre-inspection 

and post-inspection run-up and systems check. 

21. Check control stick and rudder pedals for proper movement and 

for freedom of movement. Lubricate pivot points: 

 Front _______________ 

 Rear _______________ 

22. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 11 THROUGH 22. _______________ 

 Page 31 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 3: FUSELAGE—FUEL TANK AND ENGINE SECTION

(From area of wing leading edge back to tail cone attachment bulkhead.) 

23. Inspect skin for: 

a. General condition. _______________ 

b. Loose rivets. _______________ 

c. Corrosion. _______________ 

24. Remove inspection panels and open all inspection doors to facilitate 

inspection. Inspect panels and door for: 

a. General condition. _______________ 

b. Security of hinges and attachments. _______________ 

c. Security of latching mechanisms. _______________ 

d. Lubrication—lubricate where required. _______________ 

25. Inspect control rods for general condition, security, and safetying: 

Rudder _______________

Aileron _______________

Elevator _______________

Throttle _______________

Firewall shutoff (fuel) _______________ 

26. Check controls for full travel each way. Inspect bellcranks and check for 

corrosion, general condition, security, and freedom of movement. 

Lubricate pivot points and control rod end bearings: 

Rudder _______________

Aileron _______________

Elevator _______________

Throttle _______________

Firewall shutoff (breakaway safety wire, 

both cockpits) _______________ 

Page 32 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 3: FUSELAGE—FUEL TANK AND ENGINE SECTION (Continued) 

27. Inspect fuel tanks where accessible for: 

a. General condition. _______________ 

b. Attachment and security. _______________ 

c. Leaks. _______________ 

d. Fuel line security. _______________ 

e. Security and sealing of filler cap (check gasket for condition). _______________ 

f. General condition of vent system (confirm vents are clear). _______________ 

g. Contamination (take a fuel sample from main tank sump, 

inverted tank sump, and both tip tanks). _______________ 

28. Inspect belly fuel drains to make sure that they are open. _______________ 

29. Inspect hydraulic reservoir for security. _______________ 

30. Drain hydraulic system fluid and refill reservoir with new 

MIL 5606 hydraulic fluid. Inspect gasket for condition and close 

filler cap. Inspect hydraulic pump by disconnecting the drain to the 

scavenge sump line at the hydraulic pump. If hydraulic fluid drips 

from the pump fitting, the pump should be rebuilt. _______________ 

31. Inspect nitrogen lines and attachments to hydraulic reservoir. _______________ 

32. Inspect all electrical wire bundles and Cannon plugs for: 

a. General condition. _______________ 

b. Security and attachment. _______________ 

c. Safetying, where required. _______________ 

33. Extend emergency generator and inspect for: 

a. General condition. _______________ 

b. Brush wear and seating. _______________ 

c. Commutator condition. _______________ 

d. Hydraulic actuator condition and attachment. _______________ 

 Page 33 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 3: FUSELAGE—FUEL TANK AND ENGINE SECTION (Continued) 

34. Remove, clean, inspect, reinstall, and safetie the following filters: 

a. 3 hydraulic filters. _______________ 

b. Main engine oil filter. _______________

c. Sapphire oil filter. _______________ 

d. Fuel filter of fuel oil heat exchanger. _______________ 

e. Fuel pump filter. _______________ 

f. Sapphire return fuel filter and input filter. _______________ 

g. Air filter of air starter. _______________ 

h. Air delivery controller filter for air conditioner. _______________ 

i. 2 filters of anti-G system in cockpit. _______________ 

j. Air filter of air bypass valve. _______________ 

35. Inspect Sapphire D5 starting system: 

a. General condition. _______________ 

b. For security and attachment. _______________ 

c. Compressor blades for damage. _______________ 

d. Drain oil tank, clean filter, and check magnetic plug for particles. 

Refill oil tank with Mobil Turbo 319A-2, Aeroshell Turbo Oil 3SP, 

or Ryco 481 turbine oil. _______________ 

e. Check fuel and oil lines for leaks. _______________ 

36. Inspect main engine mounts for security of attachment 

and general condition. _______________ 

37. Inspect engine control system: 

a. Throttle: 

Freedom of movement _______________ 

Full travel: idle through full _______________ 

Check stopcock position _______________ 

Functional check at engine run _______________ 

b. Fuel shutoff (firewall shutoff): 

Freedom of movement _______________ 

 Full travel _______________ 

Page 34 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 3: FUSELAGE—FUEL TANK AND ENGINE SECTION (Continued) 

c. Position fuel shutoff lever to the “on” position 

and install breakaway safety wire: 

 Front cockpit _______________ 

 Rear cockpit _______________ 

38. Check accessory drive section for: 

a. Accessory attachments. _______________ 

b. Oil, fuel, or hydraulic leaks. _______________ 

39. Inspect the bleed air bypass valve (for heating inlet of LPC) 

for general condition. _______________ 

40. Change the oil in the S-25 air starter (Mobil Jet Oil II Synthetic). _______________ 

41. Rotate the LPC with a hand crank. 

Check for ease of rotation. _______________ 

42. Check igniters for condition (do not clean). Reinstall if in 

good condition. If not, replace. _______________ 

43. Functional test igniters. (See part 2, § 5.13 of the Engine Manual.) _______________ 

44. Inspect stator and LPC blades of stage I visually through 

the air intakes for visible damage. ______________ 

45. Inspect stator and HPC blades of stage I with borescope. 

(See Engine Manual part 2, § 5.11.) Borescope: Make: _______________ 

For parameters of blade damage allowed, Model: _______________ 

refer to Engine Manual part 2, appendix 2. S/N: _______________ 

 

46. Check for easy rotation of the engine. 

(See Engine Manual part 2, appendix 3.) _______________ 

 Page 35 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 3: FUSELAGE—FUEL TANK AND ENGINE SECTION (Continued) 

47. Borescope engine and take oil sample. If the color of the engine oil 

appears dark or reddish in color, the rear seal for the hydraulic pump 

may be leaking. Run-up engine and check for leaks. _______________ 

48. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 23 THROUGH 48. _______________ 

Page 36 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 4: FUSELAGE—TAIL CONE SECTION

(From tail cone attachment bulkhead aft.)

49. Inspect 5 tail cone attachment bolts. Check torque and fit 

of safetying covers. ______________ 

50. Inspect skin for general condition, corrosion, and loose rivets: 

a. Tail cone. _______________ 

b. Horizontal stabilizer. _______________ 

c. Right elevator and trim tabs. _______________ 

d. Left elevator and trim tabs. _______________ 

e. Vertical fin. _______________ 

f. Rudder and trim tab. _______________ 

51. Remove all fairings and inspection covers. Inspect fairings 

and panels for: 

a. General condition. _______________ 

b. Security of hinges and attachments. _______________ 

c. Security of latching mechanisms. _______________ 

d. Lubrication—lubricate where required. _______________ 

52. Inspect all control rods and bellcranks for general condition, corrosion, 

and freedom of movement. Lubricate end bearings and pivot points. 

Rudder _______________

Rudder trim tab _______________ 

Left elevator _______________ 

Left elevator trim tab _______________ 

Right elevator _______________ 

Right elevator trim tab _______________ 

53. Inspect elevator counterweights for attachment, general condition, 

and security. _______________ 

54. Inspect springs and cam of elevator control assist mechanism:

a. Check that springs are in good condition. _______________ 

b. Grease cam. _______________ 

 Page 37 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 4: FUSELAGE—TAIL CONE SECTION (Continued) 

55. Move controls to stops and check angular movement. 

(Reference page 219 of Airframe and Engine Installation Manual.) 

Rudder _______________

Rudder trim tab _______________ 

Elevator _______________

Left elevator trim tab _______________ 

Right elevator trim tab _______________ 

56. Inspect electrical wire bundles and Cannon plugs for: 

a. Security. _______________ 

b. Signs of chafing. _______________ 

c. Sealing of Cannon plugs. _______________ 

57. Inspect antennae and cables for: 

a. General condition. _______________ 

b. Security and attachment. _______________ 

58. Inspect tailpipe installation for: 

a. General condition. _______________ 

b. Security and attachment. _______________ 

59. Visually inspect turbine blades through tail pipe for: 

a. General condition. _______________ 

b. Abnormal discoloration. _______________ 

60. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 49 THROUGH 60. _______________ 

Page 38 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 5: RIGHT WING AND CENTER SECTION

61. Inspect 4 fuselage-to-wing attachment fittings and bolts for: 

a. Structural integrity and general condition. _______________ 

b. Corrosion. _______________ 

c. Any indication of fretting or movement. _______________ 

d. Safetying. _______________ 

62. Jack up aircraft and inspect skin for: 

a. General condition. _______________ 

b. Security of hinges and attachments. _______________ 

c. Loose rivets. _______________ 

63. Remove all fairings and open inspection doors. Inspect for: 

a. General condition. _______________ 

b. Security of hinges and attachments. _______________ 

c. Lubrication—lubricate where required. _______________ 

64. Inspect gear doors for: 

a. General condition. _______________ 

b. Rigging. _______________ 

c. Conformity to bottom of wing when in “up” position. _______________ 

d. Hinge condition. _______________ 

e. Lubrication—lubricate hinges. _______________ 

65. Inspect up-locks (2 gear door and 1 gear) for: 

a. General condition. _______________ 

b. Lubrication—lubricate with Lubriplate grease. _______________ 

66. Inspect spring-loaded gear leg entry doors in bottom of wing for: 

a. Condition. _______________ 

b. Security. _______________ 

c. Hinge condition and lubrication. _______________ 

d. Condition of return spring. _______________ 

 Page 39 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 5: RIGHT WING AND CENTER SECTION (Continued) 

67. Inspect tire for general condition, wear, and inflation (85 PSI). 

The tire tread may be worn to the first indication of cord. 

There should be no cuts in the sidewall. _______________ 

68. Inspect oleo shock absorber for: 

a. General condition. _______________ 

b. Leaks. _______________ 

c. Extension: (2-1/4" – 2-3/4"). _______________ 

d. Wear in bottom bushing. _______________ 

69. Inspect trunion for: 

a. General condition. _______________ 

b. Corrosion. _______________ 

c. Security. _______________ 

d. Lubrication—lubricate where required. _______________ 

70. Inspect landing gear actuator for: 

a. Condition. _______________ 

b. Attachment. _______________ 

c. Leaks. _______________ 

71. Inspect landing gear door actuators for: 

a. Condition. _______________ 

b. Attachment. _______________ 

c. Leaks. _______________ 

72. Inspect hydraulic, fuel, and pneumatic lines for: 

a. General condition. _______________ 

b. Security of attachment. _______________ 

c. Corrosion. _______________

d. Leaks. _______________

Page 40 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 5: RIGHT WING AND CENTER SECTION (Continued) 

73. Inspect pitot static system: 

a. Check pitot tube for general condition and security. _______________ 

b. Check heat element. _______________ 

c. Inspect pitot static lines for security and attachment. _______________ 

d. Inspect and drain any water from moisture traps in gear wells. _______________ 

e. Conduct pitot static check after moisture traps are secured. _______________ 

74. Inspect tip tank for: 

a. General condition. _______________ 

b. Attachment to wing. _______________ 

c. Quick drain for function and leaks. _______________ 

d. Filler gasket condition. _______________ 

e. Security of fuel lines. _______________ 

f. Fiberglass tail cone condition and attachment. _______________ 

g. Leaks. _______________ 

75. Inspect nose section of tip tank: 

a. Wire bundles and Cannon plug condition. _______________ 

b. Check that Cannon plugs are sealed. _______________ 

76. Inspect aileron: 

a. Skin for condition, loose rivets, corrosion, and operational check. _______________ 

b. Structural integrity. _______________ 

c. Hinges. _______________ 

d. Control arms. _______________ 

e. Trim tab—condition and security. _______________ 

f. Trim tab—functional check. _______________ 

77. Flap inspection—remove flap to facilitate inspection: 

a. Flap skin and structure for deformation, corrosion, and loose rivets. _______________ 

b. Flap tracks for general condition, wear, signs of binding, 

cracks, and security. _______________ 

c. Flap rollers for freedom of movement and absence of corrosion. _______________ 

d. Lubricate roller and flap track with Lubriplate grease. _______________ 

e. Control arms. _______________ 

 Page 41 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 5: RIGHT WING AND CENTER SECTION (Continued) 

78. Reinstall flap and safety. _______________ 

79. Inspect all flap and aileron bellcranks and control tubes. Check for: 

a. Security and attachment. _______________ 

b. Corrosion. _______________ 

c. Free operation of bearings—lubricate. _______________ 

80. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 61 THROUGH 80. _______________

Page 42 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 6: LEFT WING AND CENTER SECTION

81. Inspect 4 fuselage-to-wing attachment fittings and bolts for: 

a. Structural integrity and general condition. _______________ 

b. Corrosion. _______________ 

c. Any indication of fretting or movement. _______________ 

d. Safetying. _______________ 

82. Jack aircraft and inspect skin for: 

a. General condition. _______________ 

b. Security of hinges and attachments. _______________ 

c. Loose rivets. _______________ 

83. Remove all fairings and open inspection doors. Inspect for: 

a. General condition. _______________ 

b. Security of hinges and attachments. _______________ 

c. Lubrication—lubricate where necessary. _______________ 

84. Inspect gear doors for: 

a. General condition. _______________ 

b. Rigging. _______________

c. Conformity to bottom of wing when in “up” position. _______________ 

d. Hinge condition. _______________ 

e. Lubrication—lubricate hinges. _______________ 

85. Inspect up-locks (2 gear door and 1 gear) for: 

a. General condition. _______________ 

b. Lubrication—lubricate with Lubriplate grease. _______________ 

86. Inspect spring-loaded gear leg entry doors in bottom of wing for: 

a. General condition. _______________ 

b. Security. _______________ 

c. Hinge condition and lubrication. _______________ 

d. Condition of return spring. _______________ 

 Page 43 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 6: LEFT WING AND CENTER SECTION (Continued) 

87. Inspect tire for general condition, wear, and inflation (85 PSI). 

The tire tread may be worn to the first indication of cord. 

There should be no cuts in the sidewall. _______________ 

88. Inspect oleo shock absorber for: 

a. General condition. _______________ 

b. Leaks. _______________ 

c. Extension (2-1/4" – 2-3/4"). _______________ 

d. Wear in bottom bushing. _______________ 

89. Inspect trunion for: 

a. General condition. _______________ 

b. Corrosion. _______________ 

c. Security. _______________ 

d. Lubrication. _______________ 

90. Inspect landing gear actuator for: 

a. Condition. _______________ 

b. Attachment. _______________ 

c. Leaks. _______________ 

91. Inspect landing gear door actuators for: 

a. Condition. _______________ 

b. Attachment. _______________ 

c. Leaks. _______________ 

92. Inspect hydraulic, fuel, and pneumatic lines for: 

a. General condition. _______________ 

b. Security of attachment. _______________ 

c. Corrosion. _______________ 

d. Leaks. _______________ 

Page 44 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 6: LEFT WING AND CENTER SECTION (Continued) 

93. Inspect pitot static system: 

a. Check pitot tube for general condition and security. _______________ 

b. Check heat element. _______________ 

c. Inspect pitot static lines for security and attachment. _______________ 

d. Inspect and drain any water from moisture traps in gear wells. _______________ 

e. Conduct pitot static check after moisture traps are secured. _______________ 

94. Inspect tip tank: 

a. General condition. _______________ 

b. Attachment to wing. _______________ 

c. Quick drain for function and leaks. _______________ 

d. Filler gasket condition. _______________ 

e. Security of fuel lines. _______________ 

f. Fiberglass tail cone for condition and attachment. _______________ 

g. For leaks. _______________ 

95. Inspect nose section of tip tank: 

a. Wire bundles and Cannon plug condition. _______________ 

b. Check that Cannon plugs are sealed. _______________ 

96. Inspect aileron: 

a. Skin for condition, loose rivets, corrosion, and operational check. _______________ 

b. Structural integrity. _______________ 

c. Hinges. _______________ 

d. Control arms. _______________ 

e. Trim tab—condition and security. _______________ 

f. Trim tab—functional check. _______________

 Page 45 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 6: LEFT WING AND CENTER SECTION (Continued) 

97. Flap inspection—remove flap to facilitate inspection: 

a. Flap skin and structure condition. 

Check for deformation, corrosion, and loose rivets. _______________ 

b. Flap tracks for general condition, wear, signs of binding, 

cracks, and security. _______________ 

c. Flap rollers for freedom of movement and absence of corrosion. _______________ 

d. Lubricate roller and flap track with Lubriplate grease. _______________ 

e. Control arms. _______________ 

98. Reinstall flap and safety. _______________ 

99. Inspect all flap and aileron bellcranks and control tubes. Check for: 

a. Security and attachment. _______________

b. Corrosion. _______________

c. Free operation of bearings—lubricate. _______________ 

100. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 81 THROUGH 100. _______________ 

Page 46 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 7: WHEELS AND BRAKES

CAUTION: Aircraft must be placed on jacks for wheel and 

brake inspection. Do not attempt to raise one wheel at a time. 

Aircraft must be jacked symmetrically using 3 jacks. 

101. Jack aircraft and place stabilizing jacks under the wings. 

a. Inspect gear assembly for hydraulic leaks and general condition: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

b. Clean the landing gear assemblies and inspect for general condition: 

Trunions, actuators, wheels, and plumbing: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

c. Remove wheels. Clean and inspect axles using at least 10X 

magnifying glass: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

d. Clean, inspect, and pack wheel bearings with grease: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

e. Clean and inspect brake assembly: 

(1) General condition: 

 Left main _______________ 

 Right main _______________ 

(2) Lining wear: 

 Left main _______________ 

 Right main _______________ 

 Page 47 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 7: WHEELS AND BRAKES (Continued) 

f. Integrity of anti-skid system: _______________ 

 Left main _______________ 

 Right main _______________

g. Reinstall wheels and bearings: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

h. Grease landing gear: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

102. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 101 THROUGH 102. _______________ 

Page 48 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 8: OPERATIONAL CHECKS

103. Electrical system operation check: 

a. Annunciator panel: 

 Front _______________ 

 Rear _______________ 

b. Navigation lights—normal and flashing: 

 Front _______________ 

 Rear _______________ 

c. Strobes. _______________ 

d. Landing light/taxi light: 

 Left _______________ 

 Right _______________ 

e. External gear extension lights: 

 Left _______________ 

 Right _______________ 

 Nose _______________ 

f. Cockpit lighting. _______________ 

g. Seat adjustment: 

 Front _______________ 

 Rear _______________ 

h. Trim tab—functional check. _______________ 

i. Operational check of inverters. _______________

j. Pitot tube heat: 

 Left _______________ 

 Right _______________ 

 Page 49 
AC 43-209 10/16/03 

Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 8: OPERATIONAL CHECKS (Continued) 

104. Hydraulic system operational check: 

a. Hook up compatible hydraulic mule: system pressure should be 150 kg/cm2

. 

b. Landing gear retraction FRONT cockpit. Smooth action— 

normal operation. _______________ 

• Gear retraction 9 +/- 1⁄2 seconds 

 (1) Door sequence: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

(2) Up-locks, normal operation:

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

(3) Gear door up-lock, normal operation:

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

c. Indicator lights: 

 3 red----------up _______________

d. Landing gear extension FRONT cockpit. Smooth action— 

 normal operation. 

• Gear extension 8 +/- 1⁄2 seconds 

(1) Door sequence: 

 Left Main _______________ 

 Right Main _______________ 

 Nose _______________ 

(2) Down-locks, normal operation:

 Left Main _______________ 

 Right Main _______________ 

 Nose _______________ 

Page 50 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 8: OPRATIONAL CHECKS (Continued)

e. Indicator lights:

 3 green----------down _______________

f. “Gear Doors Open” light on while gear is in transition. _______________

g. Landing gear retraction REAR cockpit. Smooth action— 

normal operation. _______________ 

• Gear retraction 9 +/- 1⁄2 seconds 

(1) Door sequence: 

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

(2) Up-locks, normal operation:

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

(3) Gear door up-lock, normal operation:

 Left main _______________ 

 Right main _______________ 

 Nose _______________ 

h. Indicator lights:

 3 red----------up _______________ 

i. Gear doors flush with bottom of wing when in the “up” position. _______________

j. Landing gear extension REAR cockpit. Smooth action— 

normal operation. 

• Gear extension 8 +/- 1⁄2 seconds 

(1) Door sequence: 

 Left Main _______________ 

 Right Main _______________ 

 Nose _______________ 

(2) Down-locks, normal operation:

 Left Main _______________ 

 Right Main _______________ 

 Nose _______________ 

100-HOUR INSPECTION/CONDITION INSPECTION 

 Page 51 
AC 43-209 10/16/03 

Appendix 1 

ZONE 8: OPERATIONAL CHECKS (Continued)

k. Indicator lights:

 3 green----------down _______________

l. “Gear Doors Open” light on while gear is in transition. _______________ 

m. Gear horn—wheels up and full flaps. _______________ 

n. Conduct emergency gear extension: 

 Front cockpit _______________ 

 Rear cockpit _______________

105. Flaps:

a. Extend and retract flaps from both cockpits—operation normal: _______________ 

Flap extension to takeoff-----3 +/- 2 seconds 

Flap takeoff to retraction-----3 +/- 2 seconds 

b. Indicator lights “Up”:

 Front cockpit _______________ 

 Rear cockpit _______________ 

c. Indicator lights “Take Off”:

 Front cockpit _______________ 

 Rear cockpit _______________ 

d. Indicator lights “Down”:

 Front cockpit _______________ 

 Rear cockpit _______________ 

106. Dive brakes:

a. Extend and retract from both cockpits: 

 Operation normal _______________ 

b. Indicator light:

 Front 

 Rear 

Lubricate dive brake hinges _______________ 

Lubricate dive brake actuator rod ends _______________ 

Page 52 
10/16/03 AC 43-209 

 Appendix 1 

100-HOUR INSPECTION/CONDITION INSPECTION 

ZONE 8: OPERATIONAL CHECKS (Continued)

107. Emergency generator extension and retraction:

 Operation normal _______________ 

 Lubricate hinges _______________ 

Lubricate actuator rod ends _______________ 

108. Final check: 

a. Confirm all inspection doors closed and secure. _______________ 

b. Confirm all panels and fairings are installed and secured. _______________ 

c. Registration certificate in the aircraft. _______________ 

d. Airworthiness certificate in the aircraft. _______________ 

e. Flight manual with operations limitations and weight and balance 

in the aircraft. _______________ 

f. Identification plate on left side of tail cone under horizontal 

stabilizer. _______________ 

g. Experimental decals at cockpit entrances. _______________ 

h. Jet fuel and quantity decals: 

 Top fuselage _______________ 

 Left tip _______________ 

 Right tip _______________ 

i. Conduct engine test run and systems and taxi checks as given in 

Engine Manual part 2, § 5.1. Use an engine run-up check sheet 

and include it in the maintenance records of the aircraft. _______________ 

j. Make entries in the appropriate logbooks. _______________ 

109. Close and secure all access doors. _______________ 

INSPECTOR: 

CONFIRM INSPECTION OF ITEMS 103 THROUGH 109. _______________

 Page 53 
AC 43-209 10/16/03 

Appendix 1 

400-HOUR/48-MONTH INSPECTION 

1. Remove the fuel boost pump (LUN 6280.01-8 or LUN 6280-8) and inspect: 

a. Pump: 

(1) General condition. _______________ 

(2) Condition of bearings. _______________ 

(3) Rotor condition. _______________ 

b. Pump motor:

(1) Commutator for condition. _______________ 

(2) Brushes for condition. _______________ 

c. Reassemble fuel pump. Install in aircraft and safety. _______________ 

d. Fill fuel tanks. Stop fuel operations and check gauges for accuracy. _______________ 

e. Pressurize system in accordance with the maintenance manual 

and leak-check the fuel system. _______________ 

f. Check all fuel lines for security and safety. _______________ 

2. Remove Sapphire system from the aircraft and inspect heat components. _______________ 

a. Remove, inspect, clean, and reinstall the following: 

(1) Low-pressure fuel filter. _______________ 

(2) Return fuel filter. _______________ 

(3) Fuel distributor. _______________ 

b. Inspect fuel pump of Sapphire system: 

(1) Brushes. _______________ 

(2) Commutator. _______________ 

(3) Bearings. _______________ 

(4) General condition. _______________ 

c. Reinstall Sapphire system in the aircraft: 

(1) Attachment bolts secure and safetied. _______________ 

(2) Fuel and oil lines secure and safetied. _______________ 

(3) Cannon plugs secure and safetied. _______________ 

3. Remove VG-7500 JA main generator from the aircraft and inspect: 

a. General condition. _______________ 

b. Commutator. _______________ 

c. Brushes. _______________ 

Page 54 
10/16/03 AC 43-209 

 Appendix 1 

400-HOUR/48-MONTH INSPECTION (Continued) 

4. Pressurize cockpit section and check pressure is holding within limits. _______________ 

5. Conduct engine test run and systems and taxi checks as given in 

Engine Manual part 2, § 5.1. Use an engine run-up check sheet 

and include in aircraft maintenance records. _______________ 

6. Make entries in the appropriate logbooks. _______________

Page 55 (and 56) 

10/16/03 AC 43-209 

 Appendix 2 

APPENDIX 2. L-39 EJECTION SEAT/CANOPY INSPECTION PROGRAM 

SAFETY PRECAUTIONS WHEN SERVICING EJECTION SEATS 

1. The operational use of ejection seat type VSI-BRI/L requires special knowledge of all the 

systems. Therefore, it is the owner’s responsibility to ensure that ejection seat inspections are 

performed only by an experienced person who has documentation showing that he or she has 

been properly trained by the manufacturer’s representative and is deemed competent to perform

inspections and maintenance of ejection seats installed in L-39 aircraft. It is also the owner’s 

responsibility to ensure that only current manufacturer’s data is used when inspecting and 

servicing the seat. Contact the manufacturer by mail for a list of qualified persons at Aero 

Vodochody a.s., 250 70 Odolena Voda, Czech Republic, or by their current telephone numbers, 

which may be found on their Web site at: http://www.aero.cz.

2. Follow safety precautions at all times. Ensure that the aircraft is properly grounded. 

Performance demands, labor shortcomings, and/or other reasons are no excuse for unsafe 

practices. 

3. The following actions are strictly forbidden while servicing the ejection seat, especially 

during loading and unloading the pyromechanisms or when handling the loaded seat: 

a. Smoking or using other than industry-approved explosion-proof flashlights. 

b. Having persons present who are not taking an active part in the inspection or servicing 

of the seats. 

c. Using tools other than those specified in the seat maintenance manual. 

d. Deforming or damaging the seats by forced handling. 

e. Servicing the armed ejection seats without technical supervision or training. 

4. Qualified persons performing service and maintenance of ejection seats should: 

a. Have the current instructions on storing and handling the pyrotechnical charge. 

b. Have the current operational procedures for installing, removing, maintaining, loading, 

and unloading pyromechanisms for the emergency jettison of the canopy (canopy 

jettisoning gun). 

c. Load or unload the seat ejection mechanism. Execute Seat Ejection Mechanism (TVM) 

and the ejection/jettisoning mechanism of the canopy POP only if the seat is installed in 

the aircraft and if no other servicing operations of other specialties are to be performed. 

The only exceptions are for the rocket engine URM-1, ejector of stabilizing parachute, 

Stabilizing Chute Mechanism (VMP), and Shoulder Strap Fastening (PPRP) as these 

mechanisms are being loaded. 

d. Always lock the ejection seats and the pyromechanisms, either loaded or unloaded, 

with “ground locking elements.” 

e. Execute the pyromechanism firing check using only technological pyrocartridges. 

f. Secure all locks/pins after finishing the work operations and tests of the seats. 

Page 1
AC 43-209 10/16/03 

Appendix 2 

SAFETY PRECAUTIONS WHEN SERVICING EJECTION SEATS (Continued) 

5. Remove and test seats using all needed special equipment. 

6. Do not remove and/or install the ejection seats when it is raining or snowing, or in severe 

wind or dusty conditions. Do not service the seat outside the assigned worksite. 

7. Do not park the aircraft in the hangar with the seats armed unless they are locked with 

ground-locking elements. 

a. Seal the cockpit and provide the following warning: 

“ATTENTION: PILOT SEATS ARE ARMED!” 

b. Remove the onboard battery from the aircraft, but leave the tow equipment connected. 

8. Disconnect arming cable from canopy to airframe before removing the cockpit canopy. 

Page 2
10/16/03 AC 43-209 

 Appendix 2 

SPECIFIED WORK OPERATIONS 

(WORK TO BE PERFORMED EACH 100-HOUR/CONDITION INSPECTION) 

1. Ejection Seats. 

a. Check the pyrocartridges PK-3-M-I, 

(PP-POP Alternative) PK-7T, (PP-TVM Alternative) 120-4-2785, 

and V 9960, and rocket engine URM-1 for life limits. _____________ 

NOTE: If the remaining service-life of the pyrocartridges and the 

rocket engine is shorter than 6 months, it is recommended they be 

replaced. 

b. The seat-stabilizing parachutes and the personnel-carrying 

parachutes must be removed and inspected in accordance with 

the Armament and Rescue section of the maintenance manual. _____________ 

NOTE: Seat-stabilizing parachute and personnel-carrying parachute 

maintenance will be signed off on the L-39C parachute/pyro log sheet 

every 6 months. 

2. Seat Removal. Unload the pyromechanism of the telescopic ejection 

mechanism/TVM, the pyromechanisms of PPRP, and POP. 

Remove the seat from the aircraft and position it on a special cart. 

Unload the pyromechanism of the VMP-2. _____________

NOTE: When removing the seat it is necessary that all the groundlocking pegs be in the locking openings. Separate the seat-locking 

elements from the cockpit-locking elements, which are mutually 

interconnected through the cockpit. As soon as the seat is pulled 

80 cm, lock the rocket engine URM-1. 

3. Cockpits. 

a. Check that there is no mechanical damage and no silvering 

of the canopy glass. _____________ 

b. Inspect the frame of the canopies for damage or deformation. 

Check the condition of varnish. _____________ 

c. Check the opening locks of the canopies using both 

the inner and outer lever. _____________ 

d. Remove the canopies. Test for leakage of the manifold used for 

 jettisoning canopies. _____________ 

SPECIFIED WORK OPERATIONS (Continued) 

Page 3
AC 43-209 10/16/03 

Appendix 2 

4. Specified Work Operations. 

a. Check the clearances of transversal shafts. ______________ 

b. Check the clearance limits between the finger of the transversal 

shaft and the end of the piston-rod of the cylinder of the emergency 

jettisoning system. ______________ 

c. Clean and lubricate the articulated joints of the canopy locks and 

piston rod of pyrocylinders. ______________ 

d. Check the bowden cable of each canopy handle for 

damage or deformation. ______________ 

e. Inspect the details of the aircraft emergency rescue system

for damage or deformation. ______________ 

f. Inspect and perform a system check of the emergency 

jettisoning system. ______________ 

5. Functional Tests of Ejection Seats. 

a. Set the seat mechanism to initial positions. Place the parachute into 

the seat. ______________ 

b. Load the pyromechanism VMP-2 with live pyrocartridges 

and position the shear-off locking element. ______________ 

c. Install the seat into the aircraft and load the TVM pyromechanisms, 

telescopic ejection mechanism, PPRP, and POP 

with technological cartridges. ______________ 

d. Perform the functional test of the seat ejection mechanisms for 

ejecting through the canopy. ______________ 

e. Load the pyromechanisms of TVM, PPRP, and POP with 

technological cartridges. ______________ 

f. Perform functional test of the seat mechanisms for a normal 

ejection. ______________

g. Test the seat blocking and puncture of technological cartridges. ______________

Page 4 
10/16/03 AC 43-209 

 Appendix 2 

SPECIFIED WORK OPERATIONS (Continued) 

6. Final Work Operations. 

a. Set the seat mechanisms to initial positions. Remove the 

locking elements from the URM-1 rocket engine. _______________ 

b. Load the pyromechanisms of the TVM, PPRP, and POP with live 

pyrocartridges and lock them with seat ground-locking elements. _______________ 

c. Check the locking and seals of the levers and mechanisms of 

the ejection seat. _______________ 

d. Inspect the cockpits for foreign objects. _______________ 

e. Test the opening and closing of canopies. _______________ 

7. Periodic Work Operations During Short-Duration Storing/Standing-by of Aircraft. 

a. If the aircraft is preserved, store it according to operational instructions. 

b. After every 6 months in storage, perform the 100-hour inspection items on the ejection 

seat systems and make the appropriate logbook entry. 

Page 5
AC 43-209 10/16/03 

Appendix 2 

L-39 ALBATROSS PARACHUTE/PYRO LOG SHEET

Registration Number: 

Serial Number: 

Date Armed: 

Technician’s Name: Cert. Type & Number: 

Pyrocartridge Checklist: 

1. Seat Ejection Mechanism (TVM) Mfg. Date: Due Date: 

2. Shoulder Strap Fastening (PPRP) Mfg. Date: Due Date: 

3. Stabilizing Chute Mechanism

(VMP) 

Mfg. Date: Due Date: 

4. Accelerating Engine (URM-1) Mfg. Date: Due Date: 

5. Canopy Eject Cartridge Mfg. Date: Due Date: 

Parachute Checklist: 

1. Front Seat Parachute Pl-701/L Date Repacked: By: 

2. Rear Seat Parachute Pl-701/L Date Repacked: By: 

3. Front Seat Stabilizing Chute Date Repacked: By: 

4. Rear Seat Stabilizing Chute Date Repacked: By: 

NOTE: Inspect personnel-carrying parachute every 120 days. 

Page 6 
10/16/03 AC 43-209 

 Appendix 3 

APPENDIX 3. HARD LANDING/RUNNING OFF RUNWAY/OVERSTRESS 

INSPECTION PROGRAM

This inspection is used as a guide to detect damage to the airframe, engine, and component parts 

after the aircraft has experienced a hard landing, run off the runway, or was subject to an 

overstress condition. A hard landing is when the aircraft is subject to high G forces on landing 

that may deform the airframe, engine, engine mounts, or landing gear; damage the tires; create 

fuel or fluid leaks; or injure the pilot or passenger. 

1. Main and nose landing gear for: 

a. Visual cracks, signs of nose gear twisting, or impact. _______________ 

b. Signs of cracked paint that cover hidden cracks. _______________ 

c. Alignment when viewed from 50 feet away. _______________ 

d. Damage to trailing arm of landing gear. _______________ 

e. Main gear parallel to the aircraft centerline. 

(1) Main wheels center to center—2440 mm (96.063 inches). 

(2) Left/right wheel to center of fuselage—1220 mm 

(48.031 inches). _______________ 

f. Evidence of hydraulic shocks bottoming out. _______________ 

g. Evidence of hydraulic fluid leaking. _______________ 

h. Condition, alignment, and clearance of down locks and latches. _______________ 

i. Proper gear extension and retraction operation. _______________ 

2. Main and nose wheel wells: 

a. Landing gear attach points for cracks, deformation, 

and binding. _______________ 

b. Landing gear pivot attachment points for cracks. _______________ 

c. Aircraft structure for cracks and deformation. _______________ 

d. Landing gear doors for proper fit and alignment. _______________ 

e. Check for landing gear wear at trunions or actuator end 

bearings by measuring movement of the axle. _______________ 

Tolerances are: NEW MAX ALLOWED 

In direction of flight 4 mm 6 mm

Perpendicular to direction of flight 6 mm 8 mm

Page 1 
AC 43-209 10/16/03 

Appendix 3 

APPENDIX 3. HARD LANDING/RUNNING OFF RUNWAY/OVERSTRESS 

INSPECTION PROGRAM (Continued) 

3. Aircraft wheels and tires: 

a. Wheels for cracks, scrapes, or bent or broken flanges. _______________ 

b. Wheel-half bolts for cracks. _______________ 

c. Tires for cuts, bruises, scrapes, and general condition. _______________ 

4. Top and bottom wings and related structure for: 

a. Wrinkles, oil canning, or loose or missing rivets or fasteners. _______________ 

b. Raised gaps between rivets at butt or lap joint edges. _______________ 

c. Fuel leaks. _______________ 

5. Wing interior for: 

a. Loose or missing rivets, spar, and stringer cracks. _______________ 

b. Twists or deformation. _______________ 

c. Damage and condition of flight control rods. _______________ 

d. Fuel leaks. _______________ 

6. Horizontal flight controls: 

a. Horizontal stabilizers (top/bottom) for wrinkles, oil canning, 

loose or missing rivets, damage to spars and stringers, and 

deformation of the skin around butt and lap joints. _______________ 

b. Binding and proper rigging. _______________ 

c. Cracked or broken control stops. _______________ 

d. Twist when viewed from the tip towards the fuselage. _______________ 

7. Control top and bottom flight control surfaces for: 

a. General condition, alignment, or loose or missing rivets. _______________ 

b. Proper rigging and operation. _______________ 

c. Cracks (control stops). _______________ 

Page 2 
10/16/03 AC 43-209 

 Appendix 3 

APPENDIX 3. HARD LANDING/RUNNING OFF RUNWAY/OVERSTRESS 

INSPECTION PROGRAM (Continued) 

8. Fuselage: 

a. General condition, alignment, or loose or missing rivets. _______________ 

b. Evidence that the fuselage fairings have moved. _______________ 

c. Fuel leaks. _______________

d. Flight control push-pull rods for bends, cracks, or scraping 

internal structures. _______________ 

e. Raised gaps at butt or lap joints. _______________ 

f. Fit and function. _______________ 

g. Pressurization—pressurize system. _______________ 

NOTE: Pressures are given in kg/cm2

. The pressure gauges in the 

L-39C are calibrated using this scale. To find PSI, multiply by 14.2. 

For example, if 150 kg/cm2 is indicated on the pressure gauge, multiply 

150 x 14.2 = 2130 PSI.

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