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Zlin Aviation Savage Classic Maintenance Manual

Ulm/lsa aircraft
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2, Kvetna 682
763 61 Napajedla
Czech Republic
ULM/LSA Aircraft
SAVAGE
C
lassic/Cruiser/Cub/Bobber

MAINTENANCE MANUAL

Airplane Serial Number:
Airplane Registration Number:
www.zlinaero.com
customer.service@zlinaero.com
Issued: 01/02/2006
QAP-AMM-Rev02
Date of latest Revision: 23/01/2013

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  • Page 1: Maintenance Manual

    2, Kvetna 682 763 61 Napajedla Czech Republic ULM/LSA Aircraft SAVAGE lassic/Cruiser/Cub/Bobber MAINTENANCE MANUAL Airplane Serial Number: Airplane Registration Number: www.zlinaero.com customer.service@zlinaero.com Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013...
  • Page 2 Zlin Aviation Section 0 Maintenance Manual Introduction In compliance with ASTM Standard F2483-05 INTENTIONALLY LEFT BLANK Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: ii...

  • Page 3: Log Of Revisions

    Zlin Aviation Section 0 Maintenance Manual Introduction LOG OF REVISIONS Rev. Change Date Prepared by Approved by Extended content 24-Apr-2009 Reformatted and extended content for 23-Jan-2013 compliance with ASTM F2483-05 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: iii...
  • Page 4 Zlin Aviation Section 0 Maintenance Manual Introduction LIST OF EFFECTIVE PAGES Page Number Change Date Prepared Checked Initial issue 01/02/2006 24/04/2009 General re-arrangement, improved page numbering, extended content. 23/01/2013 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: iv...

  • Page 5: Table Of Contents

    Zlin Aviation Section 0 Maintenance Manual Introduction Section 0 – INTRODUCTION TABLE OF CONTENTS Log of revisions ..............................iii List of effective pages ............................iv SECTION 0 - INTRODUCTION ..........................v 0.1 Table of contents ............................v 0.2 Scope ................................. vii 0.3 Reference Documents ..........................
  • Page 6 Zlin Aviation Section 0 Maintenance Manual Introduction 1.2.9 2000 hours inspection ......................1-39 1.3 Structures ..........................1-40 1.3.1 Fuselage ............................1-40 1.3.2 Wings ............................1-41 1.3.3 Empennage ..........................1-42 1.3.4 Landing gear ..........................1-43 1.3.5 Control surfaces .......................... 1-44 1.4 Engine ............................ 1-45 1.5 Fuel System ..........................
  • Page 7 For the SAVAGE airplanes that are not under LSA rules and when the figure of a LSRMA is not issued, all the maintenance procedures designated to a LSRMA have to be made by a Zlin Aviation s.r.o. authorized technician if it is not against the national rules of the State of registration of the airplane.

  • Page 8: Section 0 - Introduction

    Zlin Aviation Section 0 Maintenance Manual Introduction REFERENCED DOCUMENTS ASTM Standards:  F 2245 Specification for Design and Performance of a Light Sport Airplane  F 2295 Practice for Continued Operational Safety Monitoring of a Light Sport Airplane Federal Standards: ...

  • Page 9: Terminology - Definitions

    Zlin Aviation Section 0 Maintenance Manual Introduction TERMINOLOGY - DEFINITIONS 1. Annual Condition Inspection – detailed inspection accomplished once a year on a LSA in accordance with instructions provided in the maintenance manual supplied with the aircraft. The purpose of the inspection is to look for any wear, corrosion, or damage that would cause an aircraft to not be in a condition for safe operation.

  • Page 10: Significance And Use

    The purpose of this maintenance manual is to provide guidance to owners, mechanics, airports, regulatory officials, and aircraft and component manufacturers who may accomplish maintenance, repairs, and alterations on the Savage Classic, Cruiser or CUB Light Sport Aircraft. Issued: 01/02/2006...
  • Page 11 Zlin Aviation Section 0 Maintenance Manual Introduction INTENTIONALLY LEFT BLANK Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: xi...

  • Page 12: Section 1 - Aircraft Maintenance Manual

    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 either be included with the aircraft’s documentation on delivery or be available from Zlin Aviation sro or Sportair USA.

  • Page 13: Specifications And Data

    The Savage is a single engine, high wing, two seat tandem Light Sport Aircraft of classical design. It is built in the Czech Republic (Zlin Aviation sro) and in Italy (Zlin Aviation Italia srl) in full compliance with the regulations in force in both Countries, and to the requirements of the ASTM Consensus Standards for Light Sport Aircraft.
  • Page 14 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Three view drawing: Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: 1-3...

  • Page 15: Equipment List

    Aircraft Maintenance Manual 1.1.2 EQUIPMENT LIST Zlin Aviation sro retains the approval authority of any items installed in all Savage aircrafts. Therefore the following master list of equipment must be enforced as the only approved items for installation on the aircraft without further authority. No substitutions are allowed without written approval by the Manufacturer or the U.
  • Page 16 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Composite wheel pants Zlin Aviation For Cruiser Only Airframe Complete wood floorboard Zlin Aviation Ballistic parachute Zlin Aviation Junkers softpack Door key lock Zlin Aviation Towing hook system Zlin Aviation Parking brake...

  • Page 17: Source To Purchase Parts

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.1.3 SOURCE TO PURCHASE PARTS Spare parts can be ordered from different sources depending on its nature. We list here a simplified list of sources, and we encourage the owner to contact with ZA anytime a question arises about the compatibility of a product or consumable.

  • Page 18: Engine Specifications

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.1.5 ENGINE SPECIFICATIONS Engine Manufacturer: BRP Powertrain GmbH (Former Rotax GmbH). Standard Engine Model: 912 UL Optional Engine Model: 912 ULS Optional Engine Model: 914 115hp or Zlin 912 Super 120hp (turbo versions)
  • Page 19 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Coolant See engine operators manual In use of conventional coolant: Coolant temperature:(coolant exit temperature) Max..............120°C (248°F) Cylinder head temperature: Max..............135° (275°F) Permanent monitoring of coolant temperature and cylinder head temperature is necessary.

  • Page 20: Weight And Balance Information

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.1.6 WEIGHT AND BALANCE INFORMATION Note: see Savage Aircraft Pilot’s Operating Handbook, section 6, for more complete information. Introduction The Center of Gravity (C.G.) on an airplane is the point at which the plane would hang in balance, were it suspended in midair*.
  • Page 21 Aircraft Gross Weight Limit 1235 lbs Moment /Weight=CG 75,10 Datum 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 Moment Main Landing Gear L...
  • Page 22 79,34 Datum Location-Front face of engine's propeller flange Acceptable CG Range 74.0 - 80.7 Savage Classic Serial Number 0121 04/10/2007 Method 1. Multiply each item’s weight times its arm in inches to find the moment. Record each on its respective line.

  • Page 23: Tire Inflation Pressures

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.1.7 TIRE INFLATION PRESSURES Max 16psi 1.10bar Main Standard Tire Tundra Tire 8.00 6” Min 13psi 0.9bar Matco Tailwheel 32psi 2.2bar 6/12 psi (See manual provided ABI-TIRE-ICA) Alaskan Bushwheels 1.1.8 APPROVED OILS AND CAPACITIES See Rotax 912 ULS Operators Manual section 2.5...
  • Page 24 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 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 use throughout the seasons, ensure rapid lubrication of all engine components at cold start and get less fluid at higher temperatures.

  • Page 25: Recommended Fasteners Torque Values

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.1.9 RECOMMENDED FASTENER TORQUE VALUES For more in depth information please refer also to FAA Advisory Circular AC43..13 Chapter 7. For additional information about turnbuckle installation and inspection, or control cables and nicopress installation and inspection, refer to chapter 1.3.6 Control cables and pulleys.
  • Page 26 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual If there is any doubt a fastener has been under-torqued, the nut shall be backed off one complete rotation (360°) maximum and retightened to the specified value; the bolt, screw or stud must not be allowed to rotate.
  • Page 27 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Cotter Pins Securing by cotter pin is used for bolts subject to rotation. They are used because they can be removed and reinstalled quickly. The diameter of the cotter pin should be the largest size that will fit the slot in the castle nut or the hole in the bolt.
  • Page 28 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Eyebolts Inspection Cracks and subsequent failures of rod ends usually begin at the thread end near the bearing and adjacent to or under the jam nut. Typical locations for rod end cracks...

  • Page 29: General Safety Information

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.1.10 GENERAL SAFETY INFORMATION There are many hazards inherently present when performing any maintenance task on this aircraft. To minimize the risk to both yourself and others, begin by thinking through each task that is to be performed before starting any work.

  • Page 30: Flight Safety Issues Reporting Instructions

    Aircraft Maintenance Manual 1.1.11 FLIGHT SAFETY ISSUES REPORTING INSTRUCTIONS Zlin Aviation has put in place an online reporting system for any Safety of Flight or Service Difficulty issue that the owner or operator might encounter. You can easily report by entering our website in www.zlinaero.com...

  • Page 31: Inspections

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2 Inspections 1.2.1 GENERAL This section is intended to serve as a guide for a the person performing the maintenance tasks (certified airframe and powerplant mechanic, owner, LSRMA) to perform routine maintenance on the aircraft.
  • Page 32 100-hour interval. Inspection tolerances cannot be accumulated. ZLIN AVIATION S.R.O. considers the inspections described in the following chapters as mandatory/obligatory to ensure the safe operation of the Savage Aircraft. Therefore strictly follow instructions as hereunder.

  • Page 33: Daily Inspection

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.2 Daily inspection Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, panels, fairing and so on, that have been removed for the inspection.
  • Page 34 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Wings, Control Surfaces, Fuselage, external Cabin Level of certification Check windshield for dust, cracks or dents. Check fuel filler caps for Owner security Check on the wings that all vortex generators are present correctly fixed (if installed).
  • Page 35 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Landing gear Level of certification Check tire condition and pressures. Check wheel fairing if installed Owner Check landing gear structures, attachments, bolts, for condition and correct torque. Owner Check oil fitting on the brake pumps for leakages. Check wheels for status and axle bolt.
  • Page 36 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Cabin - general Level of certification Check for dust, oil leaking, or damages on the floorboard. Clean and remove Owner lost objects from the bottom of the fuselage. Check the air vents for correct operations...
  • Page 37 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.3 50 (fifty) Hours or 6 (six) Months Inspection (Whichever comes earlier) Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, fairing, seats and so on, removed for the inspection.
  • Page 38 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Propeller See propeller maintenance manual. In addition make these control: Level certification Check propeller bolts. Verify attachment bolts are in good condition LSRMA and correctly torqued. Check propeller blades and metal leading edge for condition, LSRMA indentation, stone chips.
  • Page 39 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual cables, attachments, and rudder pins. Verify horizontal trip pins secure. Verify trim control cable attachment and return spring tension (if your model is so equipped). Control for tightness the vertical bolt and nut( inside and on the rear of...
  • Page 40 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Lube axels and bearing with lubrication grease Owner Flight controls, seats, seat belts Level certification Check all control stick system and all pedal system for condition. LSRMA Check all the bolts, free correct movement and bolts and nuts.
  • Page 41 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Cabin - generals Level certification Check instruments condition, hoses, and switches efficiency. LSRMA Remove any dirt as accumulated in the cabin and ensure cleanliness OWNER between fabric cover and fuselage frame. Check for dust, oil leaking, or damages on the floorboard.
  • Page 42 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Instruments-Engine running check after inspection Instruments: Level certification 1 Check for deterioration, damage, or moisture invasion. Owner 2 Make sure instrument glasses are clean. Owner 3 Check for correct calibration. (If not they must be repaired, serviced, or re- Owner/ calibrated, before any further flight is contemplated.)
  • Page 43 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.4 50 (fifty) Hours or Annual Condition Inspection (Whichever comes first) Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, fairing, seats and so on, removed for the inspection.

  • Page 44: Hours Or Annual Condition Inspection (Wcf)

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.5 100 Hours or Annual Condition Inspection (Whichever comes first) Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, fairing, seats and so on, removed for the inspection.
  • Page 45 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Cabin Level of certification Check pilot and passenger seats for security condition. Inspect safety LSRMA belt connections and attachments. Check instruments for condition and all attachments, hoses and LSRMA switches for efficiency.
  • Page 46 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Landing gear Level of certification If it is found the tires are wearing unevenly , reverse them with the LSRMA aim of evening up the wear rate. Verify the main gear clamping bolt attachments are secure.

  • Page 47: Hours Inspection

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.6 200 (two hundred) Hours or 18 (eighteen) Months Inspection (Whichever comes first) Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, fairing, seats and so on, removed for the inspection.

  • Page 48: Hours Inspection

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.7 600 (six hundred) Hours Inspection Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, fairing, seats and so on, removed for the inspection.
  • Page 49 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Landing gear Level of certification Dismantle main landing gear and tail wheel leaf spring to verify LSRMA condition and the presence of any free play. If required, replace main landing gear attachment bolts and locking devices.

  • Page 50: Hours Inspection

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.2.8 1200 (One thousand two hundred) Hours Inspection Note: make sure that after the inspections, aircraft is free of any tools, parts and debris, and reinstall all access doors, fairing, seats and so on, removed for the inspection.

  • Page 51: Structures

    NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. Issued: 01/02/2006...

  • Page 52: Wings

    NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. For small fabric repair (patch holes and similar), refer to section 2.3.3.3 of this manual.

  • Page 53: Empennage

    NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. For small fabric repair (patch holes and similar), refer to section 2.3.3.3 of this manual.

  • Page 54: Landing Gear

    (any model). Follow installation and maintenance instructions provided with the system. NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. Issued: 01/02/2006...

  • Page 55: Control Surfaces

    NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. For metal sheet repair see 2.3.3.1.

  • Page 56: Engine

    Maintenance Manual Aircraft Maintenance Manual 1.4 Engine Zlin Aviation supplies with each LSA Aircraft all the original manuals supplied by BRP Powertrain GmbH/Rotax, for the operation and line/heavy maintenance as well as overhaul of the 912 UL and ULS engine series.

  • Page 57: Fuel System

    All fuel lines are properly supported and protected from vibration and wear. NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. Issued: 01/02/2006 QAP-AMM-Rev02...

  • Page 58: Propeller

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.6 Propeller Refer to the propeller manufacturer 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 blade c03HRC NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time.

  • Page 59: Utility Systems

    A LSRMA or A&P have to check the system during the 50 hours inspection. NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. Issued: 01/02/2006...

  • Page 60: Instruments And Avionics

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.8 Instruments and Avionics Follow original Avionics or Instruments instructions for maintenance or checks. Replace defective instruments or avionics only with approved instruments. Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013...

  • Page 61: Electrical System

    ASTM standards. NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. Issued: 01/02/2006 QAP-AMM-Rev02...
  • 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 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual Refer to FAA AC 43.13-1B Chapter 11 for the inspection and care of Aircraft Electrical Systems. Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: 1-54...
  • Page 66 Replace components of the electrical system that are damaged or defective with identical parts, with Zlin Aviation’s approved equipment. A list of suggested problems to look for and checks to be performed are:  Damaged, discolored, or overheated equipment, connections, wiring, and installations.
  • Page 67 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.9.4 CLEANING AND PRESERVATION Annual cleaning of electrical equipment to remove dust, dirt, and grime is recommended. Suitable solvents or fine abrasives that will not score the surface or remove the plating may be used to clean the terminals and mating surfaces if they are corroded or dirty.

  • Page 68: Structural Repair

    Aircraft Maintenance Manual 1.10 Structural Repair NOTE: no major repair or alteration, as outlined in ASTM 2483, are authorised at this time. For eventually obtaining engineering approval for any major repair or alteration, contact Zlin Aviation. Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013...

  • Page 69: Painting And Coatings

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.11 Painting and coatings Savage aircrafts are covered with standard dacron fabric. The covering procedure is absolutely traditional, as outlined in different specific literature, and is described in chapter 2.3.3..3. Trained A&P or LSRMA should be able to repair a tear on the dacron without any particular problems.
  • Page 70 Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1. Degrease components with an alcohol based cleaner per manufacturer’s instructions. 2. Sand with 400 grit sandpaper, blow and tack off. Preparation of fabric Smooth any edges with a small iron. Use dry 400-grit sandpaper to smooth tape and double edges and remove surface dust bumps.

  • Page 71: Feedback Form

    Zlin Aviation Section 1 Maintenance Manual Aircraft Maintenance Manual 1.12 Feedback form Maintenance, Service and Safety Report Owners are welcome to send their Service Reports, or any comments or difficulties in relation also with the use of this manual, by filling the Service Report Form in the Owner Area of our website.

  • Page 72: Section 2 - Line Maintenance, Repairs And Alterations

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations Section 2 – Line Maintenance, Repairs and Alterations SECTION 2 – LINE 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 ......................

  • Page 73: Authorization To Perform Line Maintenance

    Zlin Aviation LSA Savage aircrafts. The examples listed below are not considered as restrictions against the performance of such tasks by an owner who is authorized to perform said task by the FAA.

  • Page 74: Faa Authorization To Perform Line Maintenance

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 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 may be performed by the Pilot/Owner and who is the holder of an FAA Sport Pilot, Recreational Pilot, Private Pilot, Commercial, or Airline Transport Pilot Certificate.

  • Page 75: Line Maintenance Tasks

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations Line Maintenance Tasks 2.3.1 SERVICING OF FLUIDS This information gives the general servicing procedures and maintenance practices that are to be used when servicing the airplane. For additional detailed information concerning unit servicing of the engine, refer to the applicable chapters of the Engine Manual.

  • Page 76: Removal And Replacement Of Components

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 2.3.2 REMOVAL AND REPLACEMENT OF COMPONENTS For aircraft assembly instructions (wings, tail surfaces, etc…), please follow instructions detailed in QAP-RTF-API (Assembly procedure Instructions) manual. 2.3.2.1 STEEL WIRE CABLES AND PULLEYS The following is a partial extract from FAA AC 43.13-1B.
  • Page 77 Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations CABLE SYSTEM INSPECTION Aircraft cable systems are subject to a variety of environmental conditions and deterioration. Wire or strand breakage is easy to visually recognize. Other kinds of deterioration such as wear, corrosion, and/or distortion are not easily seen;...
  • Page 78 Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations Various cable system malfunctions may be detected by analyzing pulley conditions. These include such discrepancies as too much tension, misalignment, pulley bearing problems, and size mismatches between cables and pulleys. Examples of these condition are shown in the figure.

  • Page 79: Safety Wire Installation To Turnbuckles

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 2.3.2.2 SAFETY WIRE INSTALLATION TO TURNBUCKLES The following is a partial extract from FAA AC 43.13-1B. Before securing turnbuckles, threaded terminals should be screwed into the turnbuckle barrel until no more than three threads of either terminal are outside the barrel.

  • Page 80: Repair Of Components

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 2.3.3 REPAIR OF COMPONENTS 2.3.3.1 REPAIR OF NON STRUCTURAL SHEET METAL PARTS Level of Certification 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 Mechanic.

  • Page 81: Repair Of Non Structural Composite Materials

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 2.3.3.2 REPAIR OF NON STRUCTURAL COMPOSITE MATERIALS Level of Certification Non-structural composite 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.

  • Page 82: Repair Of Minor Fabric Damages

    The aircraft has 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.
  • Page 83 Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations PATCH REPAIR LESS THAN 8 INCHES (a) Trim any ragged edges. (b) Lay an un-shrunk piece of material over the hole and trace the outline of the patch with a #2 pencil. Make sure to allow for enough overlap as explained earlier.
  • Page 84 Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations PATCH REPAIR MORE THAN 8 INCHES (a) For large fabric repairs such as a wing tip, start at the last good rib, or at a convenient location close to the damaged area, removing the old finish tapes.

  • Page 85: Stop Drilling Of Cracks

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 2.3.3.4 STOP DRILLING OF CRACKS This is an extract of FAA AC 43.13-1B Chapter 3. Replace, rather than repair extensively damaged transparent plastic, whenever possible, since even a carefully patched part is not the equal of a new section, either optically or structurally. At the first sign of crack development, drill a small hole with a # 30 or a 1/8-inch drill at the extreme ends of the cracks as shown in figure 3-21.
  • Page 86 Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations affected area by hand, using a soft clean cloth dampened with a mixture of turpentine and chalk, or by applying automobile cleanser with a damp cloth. Remove the cleaner and polish with a soft, dry cloth.
  • Page 87 Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations the stop-drilled hole. Allow the repair to dry for about 30 minutes, and then trim the rod off flush with the sheet. Polishing and Finishing. Scratches and repair marks, within certain limitations, can be removed from acrylic plastic.

  • Page 88: Alterations

    Zlin Aviation Section 2 Maintenance Manual Line Maintenance, Repairs and Alterations 2.3.4 ALTERATIONS COMPLIANCE WITH MANUFACTURER’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 database and will be in the form of Safety Alerts, Service Bulletins, and Notifications.

  • Page 89: Section 3 - Heavy Maintenance, Repairs And Alterations

    Zlin Aviation Section 3 Maintenance Manual Heavy Maintenance, Repairs and Alterations SECTION 3 – HEAVY MAINTENANCE, REPAIRS AND ALTERATIONS 3.1 Authorization to perform heavy maintenance, repair and alterations .......... 3-2 3.2 Heavy Maintenance Tasks ......................3-2 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013...

  • Page 90: Authorization To Perform Heavy Maintenance

    Zlin Aviation Section 3 Maintenance Manual Heavy Maintenance, Repairs and Alterations Authorization 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.

  • Page 91: Section 4 - Overhaul

    Zlin Aviation Section 4 Maintenance Manual Overhaul 4 OVERHAUL 4.1 Authorization to perform overhaul……………………………………………………….. 4-2 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: 4-1...
  • Page 92 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 Aviation sro. For engine overhaul, refer to the engine manual for a list of Rotax approved service centers.

  • Page 93: Section 5 - Major Repairs And Alterations

    Zlin Aviation Section 5 Maintenance Manual Major repairs and alterations SECTION 5 – MAJOR REPAIRS AND ALTERATIONS 5.1 Authorization to perform major repairs and alterations…………………………………5.2 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: 5-1...

  • Page 94: Authorization To Perform Major Repairs And Alterations

    Zlin Aviation Section 5 Maintenance Manual Major repairs and alterations 5.1 Authorization to perform major repairs and alterations No major repairs or alterations, as outlined in ASTM F2483, FAR 43, or in this manual are authorized at this time. Issued: 01/02/2006...

  • Page 95: Section 6 - Task-Specific Training

    Zlin Aviation Section 6 Maintenance Manual Task-specific training SECTION 6 – TASK-SPECIFIC TRAINING Zlin Aviation Savage Aircraft specific training Type specific trainings: 6.2.1 Rotax maintenance course 6.2.2 EAA Sport Air Fabric Covering Course Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013...

  • Page 96: Section 7 - Safety Directives

    Zlin Aviation Section 7 Maintenance Manual Safety directives SECTION 7 – SAFETY DIRECTIVES 7.1 Continued Airworthiness Instructions.................7.2 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: 7-1...

  • Page 97: Continued Airworthiness Instructions

    The owner is responsible for ensuring that any needed corrective action is completed as specified in a notice, or by the next scheduled annual inspection. The owner shall also inform Zlin Aviation upon completion of any prescribed corrective action following a notice, using either the specific Form in the Owners Area of the website (Service Report Form, select option Attestation of Corrective Action Taken), or by filling and sending via e-mail (to: servicereports@zlinaero.com) or...
  • Page 98 Zlin Aviation, the company has created a specific online SERVICE REPORTS Form to fill in the Owner Area of the website, which allows to fully categorize, describe, and support with attached pictures the communication, ensuring also that it will be straight delivered to the responsible department of the company for immediate evaluation.

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