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 [email protected] Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 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 Zlin Aviation Section 0 Maintenance Manual Introduction LOG OF REVISIONS Rev. Change Date Prepared by Approved by PR PR NC SG PR 1 Extended content 24-Apr-2009 Reformatted and extended content for LC PR 2 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 Zlin Aviation Section 0 Maintenance Manual Introduction 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 General re-arrangement, All improved page numbering, extended content. 2 23/01/2013 LC PR 3 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: iv Zlin Aviation Section 0 Maintenance Manual Introduction Section 0 – INTRODUCTION 0.1 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 .............................................................................................................................. viii 0.4 Terminology - Definitions ........................................................................................................................... ix 0.5 Significance and use .................................................................................................................................... x SECTION 1 – AIRCRAFT MAINTENANCE MANUAL ................................................................................. 1-1 1.1 General ..................................................................................................................................... 1-1 1.1.1 Specifications and data ............................................................................................................... 1-2 1.1.2 Equipment 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 ............................................................................................................. 1-12 1.1.8 Approved oils and capacities .................................................................................................... 1-12 1.1.9 Recommended fasteners torque values ................................................................................... 1-14 1.1.10 General safety information ...................................................................................................... 1-18 1.1.11 Flight safety issues reporting instructions ................................................................................ 1-19 1.2 Inspections ............................................................................................................................. 1-20 1.2.1 General ..................................................................................................................................... 1-20 1.2.2 Daily Inspection ........................................................................................................................ 1-22 1.2.3 50 hours or six months inspection (wcf)................................................................................... 1-26 1.2.4 50 hours or Annual Condition inspection (wcf) ........................................................................ 1-32 1.2.5 100 hours inspection ................................................................................................................ 1-33 1.2.6 200 hours inspection ................................................................................................................ 1-36 1.2.7 600 hours inspection ................................................................................................................ 1-37 1.2.8 1200 hours inspection .............................................................................................................. 1-39 Issued: 01/02/2006 QAP-AMM-Rev02 Date of latest Revision: 23/01/2013 Page Number: v 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 ............................................................................................................................ 1-46 1.6 Propeller ................................................................................................................................. 1-47 1.7 Utility systems ........................................................................................................................ 1-48 1.8 Instruments and avionics......................................................................................................... 1-49 1.9 Electrical system ..................................................................................................................... 1-50 1.10 Structural repair .................................................................................................................... 1-55 1.11 Painting and coatings ............................................................................................................ 1-56 1.12 Feedback Form ...................................................................................................................... 1-58 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 ........................................................................................................... 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 and pulleys ................................................................................................ 2-5 2.3.2.2 Safety wire installation to turnbuckles ................................................................................. 2-8 2.3.3 Repair of components .................................................................................................................. 2-9 2.3.3.1 Repair of non structural sheet metal parts........................................................................... 2-9 2.3.3.2 Repair of non structural composite materials