Zlin Aviation Savage Classic, Maintenance Manual

Page 1: ...latest Revision 23 01 2013 2 Kvetna 682 763 61 Napajedla Czech Republic ULM LSA Aircraft SAVAGE Classic Cruiser Cub Bobber MAINTENANCE MANUAL Airplane Serial Number Airplane Registration Number www zl...

Page 2: ...in Aviation Section 0 Maintenance Manual Introduction Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number ii In compliance with ASTM Standard F2483 05 INTENTIONALLY LEFT BLA...

Page 3: ...1 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number iii LOG OF REVISIONS Rev Change Date Prepared by Approved by NC PR PR 1 Extended content 24 Apr 2009 SG PR 2 Reformatted and exte...

Page 4: ...P AMM Rev02 Date of latest Revision 23 01 2013 Page Number iv LIST OF EFFECTIVE PAGES Rev Page Number Change Date Prepared Checked NC All Initial issue 01 02 2006 PR PR 1 24 04 2009 SG PR 2 All Genera...

Page 5: ...nt list 1 4 1 1 3 Source to purchase parts 1 6 1 1 4 List of disposable replacement parts 1 6 1 1 5 Engine specifications 1 7 1 1 6 Weight and balance information 1 9 1 1 7 Tire inflation pressures 1...

Page 6: ...INE MAINTENANCE REPAIRS AND ALTERATIONS 2 1 2 1 Authorization to perform line maintenance 2 2 2 2 FAA Authorization to perform line maintenance 2 3 2 3 Line Maintenance Tasks 2 4 2 3 1 Servicing of fl...

Page 7: ...ruiser manufactured by Zlin Aviation sro and its components while operated as Light Sport Aircraft It also establishes guidelines for the qualifications to accomplish the specified maintenance tasks o...

Page 8: ...Safety Monitoring of a Light Sport Airplane Federal Standards 14 CFR Part 21 190 Issue of a Special Airworthiness Certificate for a Light Sport Category Aircraft 14 CFR Part 43 Maintenance Preventive...

Page 9: ...Experimental LSA do not require the individual performing maintenance to hold any FAA airman certificate in the U S 10 LSA Repairman Maintenance U S FAA certificated repairman light sport aircraft wit...

Page 10: ...onent parts meets its type design and is in a condition for safe operation Achronims 1 QAP Quality Assurance Program 2 QAM Quality Assurance Manual 3 AMM Aircraft Maintenance Manual 4 QAR Quality Assu...

Page 11: ...Zlin Aviation Section 0 Maintenance Manual Introduction Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number xi INTENTIONALLY LEFT BLANK...

Page 12: ...re parts The wiring schematic that has been included in the manual is for general information purposes only Aircraft might have optional equipment for which there are specific drawings that will eithe...

Page 13: ...ht 600kg 992 lbs 600 kg 992 lbs 600 kg 992 lbs Empty weight 288 kg 633 6 lbs 291 kg 640 lbs 296 kg 652 lbs Payload 162 kg 356 4 lbs 159 kg 349 8 lbs 154 kg 339 5 lbs Max wing loading 39 4 kg 86 9 lbs...

Page 14: ...Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 3 Three view drawing...

Page 15: ...BRP Rotax 914 O Water radiator s Zlin Aviation S Oil cooler Zlin Aviation S Auxiliary fuel pump Zlin Aviation O Cabin heater Zlin Aviation O Propeller Aerobat 72 x66SCR and 79 x52 SCR S Propeller GT G...

Page 16: ...re Zlin Aviation O IAS Zlin Aviation S Altimeter Zlin Aviation S Variometer Zlin Aviation S Slip Indicator Zlin Aviation S Compass Zlin Aviation S Radio Xcom Filser Becker O Trasponder Filser Becker O...

Page 17: ...zlinaero com eng dealers php For spare parts ordering ZA can be easily contacted at customer service zlinaero com Type Category Source Structural welded parts ZA General assemblies control surfaces co...

Page 18: ...2ULS 100 BHP at 5800 RPM NOTE refer to Engine Operators Manuals Ref OM 912 for official specifications and operational limits Description 912 ULS Bore 84 mm 3 31 in Stroke 61 mm 2 40 in Displacement 1...

Page 19: ...ad temperature is necessary Engine start operating temperature Max 50 C 120 F Min 25 C 13 F Fuel pressure Max 0 4bar 5 8 psi Min 0 15bar 2 2 psi Warning exceeding the max admissible fuel pressure will...

Page 20: ...imits to insure that the airplane can be balanced safely during flight with the trim or flight controls Operating outside of these limits will reduce the control authority of the flight controls and i...

Page 21: ...atum Location Front Face of Engine s Propeller Flange Acceptable CG Range 74 0 80 7 Engine METO 100 HP 12 8 4 Gallons Savage Classic Serial Number 0121 04 10 2007 MOST FORWARD Description Weight Arm M...

Page 22: ...3 46 13073 76 Totals 1161 5 92155 2 Aircraft Gross Weight Limit 1235 lbs Moment Weight CG 79 34 Datum Location Front face of engine s propeller flange Acceptable CG Range 74 0 80 7 Savage Classic Seri...

Page 23: ...w flyrotax com portaldata 5 dokus d05289 pdf Oil specification Use only oil with API classification SG or higher Due to the high stresses in the reduction gears oils with gear additives such as high p...

Page 24: ...1 2013 Page Number 1 13 Oil viscosity Use of multi grade oils is recommended Note multi viscosity grade oils are less sensitive to temperature variations than single grade oils They are suitable for u...

Page 25: ...essary wear of nuts and bolts as well as the parts they secure Overtorque can cause failure of a bolt or nut from overstressing the threaded areas Uneven or additional loads that are applied to the as...

Page 26: ...ew or stud must not be allowed to rotate Bolt Installation Bolts should be installed with the head forward upward or outward to the extent possible Bolts typically are not installed with the head towa...

Page 27: ...shown in the figure Safety Wire Procedure of bolt joint securing is by stainless steel wire having diameter of 0 032 The installation of safety wire is not intended to retain bolt or nut torque It is...

Page 28: ...Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 17 Eyebolts Inspection Cracks and subsequent failures of rod ends usually begin at the thread end near the bearing and...

Page 29: ...take care that no one could start the engine The activated handing of the parachute must be locked to avoid involuntary activation Never operate the engine with untrained personnel around everyone who...

Page 30: ...sue that the owner or operator might encounter You can easily report by entering our website in www zlinaero com Owner Area and then by filling the second form the one called Service Reports The corre...

Page 31: ...tions Inspection Groups and Criteria Visual Inspection Visual inspections will normally apply to those areas surfaces and or items that become visible by the removal or opening of access doors panels...

Page 32: ...Inspection Report is to be signed off in the log book maintenance record The inspection items to be covered in the condition inspection are identical to the 100 hour Inspection items The inspection in...

Page 33: ...r Check fuel oil and water hoses condition Owner Check water radiator condition and cooling fluid level Check the plastic bottle Owner Check oil radiator condition Owner Oil quantity within designated...

Page 34: ...eck for right movements and for the correct connection between the push pull tube and horn coming from the cabin and connected to the elevators with two uniball and two bolts with castle nuts and pins...

Page 35: ...3 Check aileron wires lower joins and pulleys Check that all the wire cables are correctly working inside the pulley and that have not slipped outside of it Owner 4 Check flap cable and bungee Pins an...

Page 36: ...mplete a proper purge to ensure fuel is not contaminated with water or other foreign material Owner 3 Check fuel filter condition if necessary replace with a new one Owner LSRMA 4 Ensure vent holes an...

Page 37: ...ify accessories attachments are secure Oil quantity within designated limits Check oil radiator and his aluminium box Control fixation and shock absorber Control the correct fixation of the oil tank t...

Page 38: ...external paint Owner 4 Clean the external bottom of the fuselage from oil or dust Owner 5 Inspect for condition the engine cowling and spinner Owner 6 Visual inspection of the top of the wing Clean an...

Page 39: ...joints on the controls hinges and rod end bearings and on the horizontal stabilizer fitting Landing gear Level of certification 1 Check main landing gear attachment bolts for security LSRMA 2 Verify...

Page 40: ...all flap control system and lube it Owner 7 Inspect flap control cables turnbuckles and bungee LSRMA 8 Check trim control friction and security Lube as required LSRMA 9 Check bolts securing the entire...

Page 41: ...damage Owner 3 Check the correct fixation of radio antennas cables Check the breakers Owner Level of certification 1 Check instruments condition hoses and switches efficiency LSRMA 2 Remove any dirt a...

Page 42: ...ght is contemplated Owner LSRMA 4 Ensure Pitot tube and static ports are free Owner 5 Check for correct adhesive arcs on instruments Owner 6 Control the correct push pull movement of the choke and hea...

Page 43: ...eats and so on removed for the inspection Complete entries in log book or any other required records Level of certification LSRMA You must make a visual check of all stainless steel plates and cables...

Page 44: ...the fabric covered parts LSRMA 3 Check windscreen and all windows for condition Verify all glasses correctly open and close and ensure door hinges are in good condition Grease hinges Owner 4 Check win...

Page 45: ...SRMA 7 Check flap recovery rubbers and command lever and bolt Free from excessive play LSRMA 8 Check throttle lever for freedom of movement Check friction control is in good condition and working LSRM...

Page 46: ...the main gear clamping bolt attachments are secure LSRMA 3 Verify tire pressures are correct LSRMA 4 Check braking action If required purge bleed Ensure hydraulic reservoir oil level is correct Check...

Page 47: ...nding gear pedals hinges and engine mount for stress cracking Note any displacement of paint that would indicate a problem exists LSRMA Engine See engine maintenance manual In addition make these cont...

Page 48: ...nce the propeller LSRMA Controls generals Wings Level of certification Check and adjust control cable for stiffness security and freedom of movement Rectify and adjust as required LSRMA Change all the...

Page 49: ...ntle main landing gear and tail wheel leaf spring to verify condition and the presence of any free play If required replace main landing gear attachment bolts and locking devices LSRMA 2 Dismantle mai...

Page 50: ...ctions carried out the following must be done at 1200 hours total airframe time Level of certification Repeat all previous inspection schedules and in particular the 600 hour inspection LSRMA Remove a...

Page 51: ...over long distances Type approved 4 point seat belts increase the overall sensation of safety provided by the Savage The fuselage is covered with a 3 6oz Dacron fabric which is UV treated and finishe...

Page 52: ...6oz Dacron fabric which is sewed to the ribs on both the upper and the lower wing surface Wing struts and jury struts are of extruded aviation grade alloy There are some easily removable round inspect...

Page 53: ...or electrical trim surface The horizontal fins with attached elevators can be folded upwards for storage or transport by trailer Ample control surface area provides positive control about all axes Th...

Page 54: ...h allows it to swivel freely to reduce the turning radius Optional extended gear is just longer but for the inspections point of view has no difference Alaskan Bushwheels or 26 Goodyear tires can be f...

Page 55: ...actuated with the cloche while flaps are mechanically actuated with a Bowden by moving the flap lever located on the side of the seat on the floorboard The flap lever has a spring latch system that ho...

Page 56: ...ies all pertinent information for daily checks and operation instructions See the engine maintenance manual for the instruction about maintenance repair and overhaul In addition a LSRMA or A P have to...

Page 57: ...ting in the right side This joint has also a fuel selector that allows to drain outside of the plane the necessary amount of fuel to be checked before take off see the inspections list There is a shut...

Page 58: ...r instructions for proper maintenance Propellers approved for Savage Aircraft are Approved propellers are GT Tonini Fixed Pitch Wooden GT 130 135 AEROBAT 72 x66SCR and 79 x52 SCR Warp Drive three blad...

Page 59: ...tion check that the source is correctly fixed check the system for correct function check the integrity of the cables Engine mount gauge optional The airplane is equipped with a pressure gauge in the...

Page 60: ...al Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 49 1 8 Instruments and Avionics Follow original Avionics or Instruments instructions for maintenance or checks Repla...

Page 61: ...nimize the possibility of failure 1 9 2 Description The Electrical system consists of a dry cell type 12 volt battery mounted aft in the fuselage a generator internal to the Rotax engine a voltage reg...

Page 62: ...Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 51...

Page 63: ...Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 52...

Page 64: ...Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 53...

Page 65: ...aintenance Manual Aircraft Maintenance Manual Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 54 Refer to FAA AC 43 13 1B Chapter 11 for the inspection and care of Air...

Page 66: ...installations Excessive heat or discoloration at high current carrying connections Misalignment of electrically driven equipment Poor electrical bonding broken disconnected or corroded bonding strap...

Page 67: ...rting and burning Be sure that protective finishes are not scored or damaged when cleaning Ensure that metal to metal electrically bonded surfaces are treated at the interface with a suitable anti cor...

Page 68: ...2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 1 57 1 10 Structural Repair NOTE no major repair or alteration as outlined in ASTM 2483 are authorised at this time For eventually obt...

Page 69: ...o Don t use a sponge that could be contaminated with particles e g bud fine sands etc This will avoid to grind the surface Use a separate sponge to clean the bottom of the fuselage since it is normall...

Page 70: ...remove surface dust bumps 3M 8500 Sealant or equivalent can be used to cover seams in corners as needed Painting The final finish is either a polyurethane DUHS paint from PPG as used and endorsed by Z...

Page 71: ...te Current contact information Name ____________________________________________ Address __________________________________________ Telephone ________________________________________ Cell Phone ______...

Page 72: ...ance 2 2 2 2 FAA Authorization to perform line maintenance 2 3 2 3 Line Maintenance Tasks 2 4 2 3 1 Servicing of fluids 2 4 2 3 2 Removal and replacement of components 2 5 2 3 2 1 Steel wire cables an...

Page 73: ...AA Typical Tasks Considered as Line Maintenance Include 1 100 hour inspection See Section 1 2 2 Annual condition inspection See Section 1 2 3 Servicing of fluids 4 Removal and replacement of component...

Page 74: ...r 2 3 2 2 FAA Authorization to perform line maintenance The tasks listed in this Manual and considered to be Minor Maintenance Repairs or Alteration tasks as defined in ASTM F2483 Section 3 1 12 and m...

Page 75: ...ter areas special care should be taken to keep the engine accessories and airframe clean to help prevent oxidation Lubrication table AREA Lubrication area Interval Lubricant Engine Throttle control ca...

Page 76: ...ed Do not subject wires and cables to excessive temperature Soldering the bonding braid to the control cable is not permitted Ball and Socket Type Terminals Do not use ball and socket type terminals o...

Page 77: ...elix as it was manufactured Broken wires of this type may show up as a hairline crack in the wire If a broken wire of this type is suspected further inspection with a magnifying glass of 7 power or gr...

Page 78: ...ure that defection angles are no greater than 3 maximum Determine that all guides and anti abrasion strips are secure and in good condition CORROSION AND RUST PREVENTION To ensure a satisfactory servi...

Page 79: ...alf on bottom The ends of the wires are passed through the hole in the turnbuckle eyes or between the jaws of the turnbuckle fork as applicable The wires are then bent toward the center of the turnbuc...

Page 80: ...Non structural sheet metal repairs are to be accomplished by a certificated LSA Repairman Maintenance Rated and FAA certified LSA Pilot Owner or a suitably qualified and experienced FAA certified A P...

Page 81: ...e materials repairs are to be accomplished by a certificated LSA Repairman Maintenance Rated and FAA certified LSA Pilot Owner or a suitably qualified and experienced FAA certified A P Mechanic Author...

Page 82: ...been covered using a process that is proprietary to Zlin Aviation sro It is similar to the Poly Fiber Aircraft coating process more commonly referred to as the Stits method FABRIC REPAIRS The decisio...

Page 83: ...s two applications Each application consists of 2 coats The first coat should be brushed on to penetrate the fabric After the first coat has flashed off apply the second coat by brushing or spraying o...

Page 84: ...ap over the rib d Glue a whole new piece of fabric to cover the wingtip with a 2 inch overlap over the rib area e Heat shrink f Apply the first application of Poly Brush as described previously g Secu...

Page 85: ...LEANING AND POLISHING TRANSPARENT PLASTIC Plastics have many advantages over glass for aircraft use but they lack the surface hardness of glass and care must be exercised while servicing the aircraft...

Page 86: ...el at ordinary room temperature In clamping or bolting plastic panels into their mountings do not place the plastic under excessive compressive stress It is easy to develop more than 1 000 psi on the...

Page 87: ...Acrylic windshields and windows may be cleaned by washing them with mild soap and running water Rub the surface with your bare hands in a stream of water Follow with the same procedure but with soap...

Page 88: ...NUFACTURER S SERVICE DIRECTIVES When service directives are issued they will be in the form described in Section 7 of this manual These will be sent to the owner operators in the most current ZA datab...

Page 89: ...pairs and Alterations Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 3 1 SECTION 3 HEAVY MAINTENANCE REPAIRS AND ALTERATIONS 3 1 Authorization to perform heavy maintena...

Page 90: ...horization to perform heavy maintenance repair and alterations No heavy maintenance major repair or alterations as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time 3 2 Heavy...

Page 91: ...Zlin Aviation Section 4 Maintenance Manual Overhaul Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 4 1 4 OVERHAUL 4 1 Authorization to perform overhaul 4 2...

Page 92: ...on 23 01 2013 Page Number 4 2 4 1 AUTHORISATION TO PERFORM OVERHAUL No overhauls as outlined in ASTM F2483 FAR 43 or in this manual are authorized at this time Overhauls can only be performed by Zlin...

Page 93: ...enance Manual Major repairs and alterations Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 5 1 SECTION 5 MAJOR REPAIRS AND ALTERATIONS 5 1 Authorization to perform majo...

Page 94: ...terations Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 5 2 5 1 Authorization to perform major repairs and alterations No major repairs or alterations as outlined in A...

Page 95: ...sued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 6 1 SECTION 6 TASK SPECIFIC TRAINING 6 1 Zlin Aviation Savage Aircraft specific training 6 2 Type specific trainings 6 2 1...

Page 96: ...ation Section 7 Maintenance Manual Safety directives Issued 01 02 2006 QAP AMM Rev02 Date of latest Revision 23 01 2013 Page Number 7 1 SECTION 7 SAFETY DIRECTIVES 7 1 Continued Airworthiness Instruct...

Page 97: ...nd latest versions of the Manuals will be made available for download in the Owner Area of the website When and if corrective action is determined by Zlin Aviation to be warranted Zlin Aviation will i...

Page 98: ...rection is found necessary and the airplane s restored continued airworthiness Requirement for providing alternative data and contact details for Continued Airworthiness In relation with the requireme...