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Zlin Aviation Savage Cub - User Manual

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Issued: 01/02/2006 QAP-AMM-Rev02
Date of 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.zlinaero.com
customer.service@zlinaero.com

Table of Contents

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Summary

Section 0 Introduction

0.2 Scope

Defines the content and structure of the maintenance manual for Savage LSA Aircraft.

0.3 Reference Documents

Lists ASTM standards, Federal standards, and technical documents relevant to the manual.

0.4 Terminology - Definitions

Provides definitions for terms used in the maintenance manual.

0.5 Significance and Use

Explains the purpose of the manual and its intended audience.

Section 1 Aircraft Maintenance Manual

1.1 General

General information about the manual, its structure, and purpose.

1.1.1 Specifications and Data

Technical specifications and physical data for Savage aircraft models.

1.1.2 Equipment List

List of standard and optional equipment installed on Savage aircraft.

1.1.3 Source to Purchase Parts

Information on where to obtain spare parts for the aircraft.

1.1.4 List of Disposable Replacement Parts

Lists commonly replaced parts and their sources/brands.

1.1.5 Engine Specifications

Detailed specifications for the Rotax 912 UL and ULS engines.

1.1.6 Weight and Balance Information

Procedures and data for calculating aircraft weight and center of gravity.

1.1.7 Tire Inflation Pressures

Recommended tire inflation pressures for different tire types.

1.1.8 Approved Oils and Capacities

Approved engine oils and their required capacities.

1.1.9 Recommended Fastener Torque Values

Guidelines and values for applying correct torque to fasteners.

1.1.10 General Safety Information

Essential safety practices and precautions for aircraft maintenance.

1.1.11 Flight Safety Issues Reporting Instructions

Procedures for reporting safety issues and service difficulties.

1.2 Inspections

Overview of inspection types and general inspection criteria.

1.2.1 General

General guidelines and responsibilities for aircraft inspections.

1.2.2 Daily Inspection

Tasks to be performed during the daily pre-flight inspection.

1.2.3 50 (fifty) Hours or 6 (six) Months Inspection

Maintenance tasks for the 50-hour or 6-month inspection.

1.2.4 50 (fifty) Hours or Annual Condition Inspection

Tasks for the 50-hour or annual condition inspection.

1.2.5 100 Hours or Annual Condition Inspection

Maintenance tasks for the 100-hour or annual condition inspection.

1.2.6 200 (two hundred) Hours or 18 (eighteen) Months Inspection

Maintenance tasks for the 200-hour or 18-month inspection.

1.2.7 600 (six hundred) Hours Inspection

Additional tasks for the 600-hour inspection.

1.2.8 1200 (One thousand two hundred) Hours Inspection

Tasks required at 1200 hours total airframe time.

1.2.9 2000 (Two thousand) Hours Inspection

Inspection and overhaul requirements at 2000 hours.

1.3 Structures

Description of the aircraft's structural components.

1.3.1 Fuselage

Details on the aircraft fuselage construction and access panels.

1.3.2 Wings

Description of wing construction, flaps, and materials.

1.3.3 Empennage

Details on the tail structure, rudder, and elevators.

1.3.4 Landing Gear

Description of the conventional landing gear and optional systems.

1.3.5 Control Surfaces

Information on ailerons, flaps, rudder, and elevator construction.

1.4 Engine

Information regarding engine maintenance and visual inspection points.

1.5 Fuel System

General description of the aircraft's fuel system configuration.

1.6 Propeller

Approved propellers and reference to manufacturer instructions.

1.7 Utility Systems

Description of vent system, 12V source, engine mount gauge, and heater system.

1.8 Instruments and Avionics

Guidance for maintenance and checks of instruments and avionics.

1.9 Electrical System

General information and description of the aircraft's electrical system.

1.9.3 Inspection and Operation Checks of Electrical System

Procedures for inspecting and checking the electrical system.

1.9.4 Cleaning and Preservation

Recommended procedures for cleaning electrical equipment.

1.9.5 Battery Electrolyte Corrosion

Methods for removing and neutralizing battery electrolyte corrosion.

1.10 Structural Repair

Note regarding authorization for structural repairs.

1.11 Painting and Coatings

Procedures for painting and coating aircraft surfaces.

1.12 Feedback Form

Form for submitting maintenance, service, and safety reports.

Section 2 Line Maintenance, Repairs and Alterations

2.1 Authorization to Perform Line Maintenance

Guidelines on who can perform line maintenance tasks on Savage aircraft.

2.2 FAA Authorization to Perform Line Maintenance

FAA authorization requirements for performing minor maintenance tasks.

2.3 Line Maintenance Tasks

Overview of line maintenance tasks and their recommended intervals.

2.3.1 Servicing of Fluids

General procedures for servicing aircraft fluids and lubrication.

2.3.2 Removal and Replacement of Components

Instructions for removing and replacing aircraft components.

2.3.2.1 Steel Wire Cables and Pulleys

Procedures for maintaining and replacing steel wire cables and pulleys.

2.3.2.2 Safety Wire Installation to Turnbuckles

Method for installing safety wire on turnbuckles.

2.3.3 Repair of Components

General guidance for repairing aircraft components.

2.3.3.1 Repair of Non Structural Sheet Metal Parts

Procedures for repairing non-structural sheet metal components.

2.3.3.2 Repair of Non Structural Composite Materials

Procedures for repairing non-structural composite materials.

2.3.3.3 Repair of Minor Fabric Damages

Methods for repairing minor fabric damages on the aircraft.

2.3.3.4 Stop Drilling of Cracks

Techniques for stopping cracks in plastic components.

2.3.4 Alterations

Information on compliance with manufacturer's service directives.

Section 3 Heavy Maintenance, Repairs and Alterations

3.1 Authorization to Perform Heavy Maintenance, Repair and Alterations

Statement on authorized heavy maintenance and repairs.

3.2 Heavy Maintenance Tasks (Not Authorized at This Time)

List of heavy maintenance tasks not currently authorized.

4 Overhaul

4.1 Authorization to Perform Overhaul

Information on authorized overhaul procedures and locations.

Section 5 Major Repairs and Alterations

5.1 Authorization to Perform Major Repairs and Alterations

Statement on authorized major repairs and alterations.

Section 6 Task-Specific Training

6.1 Zlin Aviation Savage Aircraft Specific Training

Information on specific training for Savage aircraft.

6.2 Type Specific Trainings

List of type-specific training courses available.

Section 7 Safety Directives

7.1 Continued Airworthiness Instructions

Instructions for maintaining continued airworthiness of the aircraft.

Service Difficulties and Safety of Flight Issues

Procedures for reporting and addressing service difficulties and safety issues.

Zlin Aviation Savage Cub Specifications

General IconGeneral
ManufacturerZlin Aviation
ModelSavage Cub
EngineRotax 912 ULS
Seats2
TypeLight aircraft
Length6.71 m (22 ft 0 in)
Maximum Takeoff Weight600 kg
Power100 hp
Stall Speed65 km/h (40 mph, 35 kn)
Range650 km
Empty Weight325 kg
Service Ceiling4, 000 m

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