ICP SAVANNAH S User manual
MAINTENANCE MANUAL
SAVANNAH S
Doc. No.:
MM-SVNH-EN
Revision:
07
Rev. Date:
07/11/2022
Proj. Ref.:
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A/C: Savannah S
Applies to Generic Serial Number: yy-mm-54-xxxx
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I.C.P. Srl
MM-SVNH-EN
MAINENANCE MANUAL
ICP SAVANNAH STM
Function
Name
Signature
Prepared
TECNIC - Technical Manager
Federico Peronato
CONF - Configuration Manager
Andrea Lisa
Verified
TECNIC - Technical Manager
Federico Peronato
Approved
DIG - Accountable Manager
Tancredi Razzano
Manufacturer data:
Name:
I.C.P. Srl
Contacts:
Phone
+39 011 9927503
Address:
S.P. 16 km 15,150
Website:
www.icp.it
Castelnuovo Don Bosco
Email:
(AT) Italy , 14022
Airworthiness:
The technical data and the information embodied therein are property of I.C.P. Srl and shall not be
disclosed in whole or in part to third parties, without prior written permission of I.C.P. Srl. Themanual
must remain with the aircraft in case of sale.
Serial Number:
Generic YY-MM-54-XXXX
Year 20YY
MAINTENANCE MANUAL
SAVANNAH S
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0.1. Amendment record
Revision
Date
Description
Issued by
00
15/11/2009
First issue
Andrea Caglio
01
21/07/2010
Ch. 3, 4, Pag. 11, 12
Andrea Caglio
02
29/04/2010
Ch. 3, Pag. 9
Andrea Caglio
03
19/05/2011
Ch. 3
Andrea Caglio
04
11/03/2015
General revision, all Pag.
Michele Bassetti
05
22/06/2016
Ch. 3.7, Pag. 11, 12
Michele Bassetti
06
18/12/2018
Ch. 1, Pag. 1, 3
Federico Peronato
07
07/11/2022
New issue of the Maintenance Manual,
superseding all the previous versions
Federico Peronato
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0.2. Table of content
0.1. Amendment record...........................................................................................................2
0.2. Table of content................................................................................................................3
0.3. Figure Index......................................................................................................................6
0.4. Table Index.......................................................................................................................7
0.5. List of Effective Pages ......................................................................................................8
1. General Information.................................................................................................................9
1.1. Meaning of WARNING, CAUTION and NOTE ................................................................10
1.2. Technical documentation................................................................................................11
1.3. Aircraft identification placard...........................................................................................11
1.4. Authorized personnel......................................................................................................11
1.5. Spare parts purchase......................................................................................................12
1.6. Warranty.........................................................................................................................13
1.7. Maintenance Request Form to ICP manufacturer...........................................................13
1.8. Feedback Form to ICP manufacturer..............................................................................13
1.9. Aircraft protection and anchoring ....................................................................................14
1.10. Aircraft cleaning ..........................................................................................................14
1.11. Consumable materials.................................................................................................15
1.12. Nominal diameters ......................................................................................................16
1.13. Tightening torques.......................................................................................................16
1.14. Safetying practices......................................................................................................19
1.14.1. Safety wires .........................................................................................................19
1.14.2. Castle nut and cotter pin ......................................................................................20
1.14.3. Threaded fasteners..............................................................................................21
1.14.4. Bolt-Nut cross-check mark ...................................................................................22
1.14.5. Pop riveting..........................................................................................................22
1.14.6. Solid riveting ........................................................................................................22
1.14.7. Cable nonio tender...............................................................................................23
1.14.8. Hose assembly.....................................................................................................23
1.15. Tools...........................................................................................................................25
1.15.1. Standard maintenance tools.................................................................................25
1.15.2. Unusual maintenance tools..................................................................................25
1.15.3. Auxiliary tools (part of the aircraft kit) ...................................................................26
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1.15.4. Measuring tools....................................................................................................26
1.16. Terms and Definitions .................................................................................................26
1.17. Airworthiness Limitations.............................................................................................27
1.18. Maintenance interval tolerances..................................................................................27
1.19. Aircraft lifting ...............................................................................................................27
1.19.1. Engine lifting ........................................................................................................28
1.20. Aircraft Levelling..........................................................................................................28
1.21. Aircraft weighing..........................................................................................................28
1.22. Fuel and fluids draining ...............................................................................................29
1.24. Aircraft approved documentation.................................................................................30
1.25. Unit conversions..........................................................................................................30
2. Daily Pre-Flight Check...........................................................................................................31
3. Time limits .............................................................................................................................35
4. Maintenance Schedule ..........................................................................................................37
4.1. 50 Hours maintenance checklist.....................................................................................39
4.2. 100 Hours / 1 Year maintenance checklist......................................................................55
4.3. 200 Hours maintenance checklist ...................................................................................57
4.4. 1000 hours maintenance checklist..................................................................................59
4.5. 2000 Hours maintenance checklist .................................................................................64
5. Unscheduled Maintenance.....................................................................................................67
5.1. Heavy landing.................................................................................................................67
5.2. Fuel system leakage in fuselage.....................................................................................68
5.3. Wing tank or cup fuel leakage.........................................................................................68
5.4. Radiator suspension breakage .......................................................................................68
5.5. Windshield or window cracks or breakage......................................................................68
5.6. Object strike the structure...............................................................................................69
5.7. Propeller strike................................................................................................................69
5.8. Engine failure..................................................................................................................69
5.9. Engine parameter exceeding..........................................................................................69
5.10. Noncompliance with fuel quality ..................................................................................69
5.11. Noncompliance with engine fluid quality......................................................................69
5.12. Noncompliance with brake oil quality...........................................................................70
5.13. Electric circuit overload (breaker out) ..........................................................................70
5.14. Flight envelope exceeding...........................................................................................70
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5.14.1. Airspeed exceeding..............................................................................................70
5.14.2. Airspeed exceeding with high turbulence .............................................................70
5.14.3. Load factor exceeding..........................................................................................70
5.14.4. Flap overspeed ....................................................................................................71
5.14.5. Take-off mass exceeding .....................................................................................71
6. Aircraft and Systems description............................................................................................73
6.1. Airframe..........................................................................................................................73
6.2. Controls..........................................................................................................................78
6.3. Powerplant......................................................................................................................79
6.3.1. Engine.....................................................................................................................79
6.3.2. Propeller..................................................................................................................79
6.4. Fuel system....................................................................................................................80
6.5. Oil system.......................................................................................................................82
6.6. Cooling system...............................................................................................................83
6.7. Brake system..................................................................................................................85
6.8. Cabin heating and ventilation..........................................................................................86
6.9. Electrical system.............................................................................................................87
6.10. Configuration, equipment, instruments and avionics....................................................89
6.11. Painting.......................................................................................................................95
7. Maintenance descriptions ......................................................................................................97
7.1. Control surface travel setting ..........................................................................................97
7.1.1. Flaperon as aileron..................................................................................................97
7.1.2. Flap indications......................................................................................................100
7.1.3. Flight check of Flaperons.......................................................................................100
7.1.4. Elevator control system..........................................................................................100
7.1.5. Rudder control system...........................................................................................103
7.1.5.1. Rudder pedals alignment to rudder and nose wheel.......................................103
7.1.5.2. Rudder ground adjustable (flettner) tab deflection...........................................104
7.1.6. Elevator Trim Tab setup.........................................................................................104
7.1.7. Tail wheel landing gear (if configured with)............................................................105
7.1.8. Brake pedals position on Rudder pedals................................................................105
7.2. Control surface free play with controls locked...............................................................105
7.3. Control surfaces hinges................................................................................................106
7.4. Fuel system drainage....................................................................................................106
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7.5. Brakes system bleeding................................................................................................106
7.5.1. Brakes oil pumps acceptable leaking.....................................................................107
7.6. Brake pads change.......................................................................................................107
7.7. Engine oil level verification............................................................................................108
7.8. Oil change ....................................................................................................................108
7.9. Coolant level verification...............................................................................................109
7.10. Coolant change.........................................................................................................109
7.11. Air filter......................................................................................................................110
7.12. Tyre change..............................................................................................................110
7.13. Windshield cracks .....................................................................................................111
7.14. Wheel fairing cracks..................................................................................................111
8. Maintenance / Service Bulletin / Change & Repair record tables..........................................113
ANNEX A - Request of Technical Intervention on the Aircraft .....................................................119
ANNEX B - Feedback about ICP Aircraft ....................................................................................121
ANNEX C - Maintenance work record Model ..............................................................................123
0.3. Figure Index
Figure 1: Safety wires example.....................................................................................................20
Figure 2: Cotter pin example.........................................................................................................20
Figure 3: Threaded fasteners........................................................................................................22
Figure 4: Nonio cable tender.........................................................................................................23
Figure 5: Fuel hose on fitting.........................................................................................................23
Figure 6: Fuel hose on corrugated pipe.........................................................................................24
Figure 7: Oil hose on corrugated pipe...........................................................................................24
Figure 8: Water hose on corrugated pipe......................................................................................24
Figure 9: Daily pre-flight check sequence plan view......................................................................31
Figure 10: Main landing gear spring design nominal dimensions (unloaded).................................67
Figure 11: Cabin floor ...................................................................................................................74
Figure 12: Fuselage rear cone......................................................................................................74
Figure 13: Cabin frame and windshield.........................................................................................75
Figure 14: Left wing ......................................................................................................................75
Figure 15: Left inboard flaperon....................................................................................................76
Figure 16: Left outboard flaperon..................................................................................................76
Figure 17: Stabilizer......................................................................................................................76
Figure 18: Elevator........................................................................................................................77
Figure 19: Fin and Rudder............................................................................................................77
Figure 20: Longitudinal and lateral controls...................................................................................78
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Figure 21: Directional controls.......................................................................................................78
Figure 22: Airframe fuel system parts............................................................................................80
Figure 23: Wing standard fuel system...........................................................................................80
Figure 24: Wing double fuel tank system (interconnected tanks)...................................................81
Figure 25: Wing double fuel tank system with transfer pumps.......................................................81
Figure 26: Fuselage and Rotax 912 UL/ULS fuel system..............................................................81
Figure 27: Fuselage Rotax 912 iS fuel system..............................................................................82
Figure 28: Rotax 912 UL/ULS/iS standard oil system....................................................................82
Figure 29: Rotax 912 UL/ULS/iS oil system with thermostat .........................................................83
Figure 30: Rotax 912 UL/ULS/iS standard cooling system............................................................84
Figure 31: Rotax 912 UL/ULS/iS cooling system with thermostat..................................................84
Figure 32: Standard brake system (only right side is shown, the left is identical, symmetrical)......85
Figure 33: Brake systemwith parking brake (only right side isshown, the left is identical, symmetrical)
.....................................................................................................................................................85
Figure 34: Double side brake system (only right side is shown, the left is identical, symmetrical) .86
Figure 35: Cabin heating system...................................................................................................86
Figure 36: Electrical wiring of engine compartment.......................................................................87
Figure 37: Electrical wiring firewall backward................................................................................88
Figure 38: Flaperon jig SA200VG and position on the first wing rib...............................................98
Figure 39: Position of jig SA200VG near the first rib rivets line, aligned to wing trailing edge........98
Figure 40: ZERO setting of the left inner Flaperon. Marks of +/- 0.5° of tolerance.........................99
Figure 41: Push-pull rods for Flaperon setup ................................................................................99
Figure 42: Digital spirit level position on Stabilizer for Zeroing.....................................................101
Figure 43: Longitudinal line bell crank on the full nose up position, against stop.........................102
Figure 44: Digital spirit level position on Elevator........................................................................102
Figure 45: Elevator final setup deflection angle...........................................................................103
Figure 46: Control surfaces hinges .............................................................................................106
Figure 47: Brake pump (seen horizontally, not vertically like the airplane installation).................107
0.4. Table Index
Table 1: Authorized personnel in function of the maintenance work..............................................12
Table 2: Consumable materials.....................................................................................................15
Table 3: Nominal diameters..........................................................................................................16
Table 4: Tightening torques for standard application.....................................................................16
Table 5c (a-c): Tightening torques for unusual application............................................................19
Table 6: Cotter pin coupling with castle nut...................................................................................21
Table 7: Standard tools.................................................................................................................25
Table 8: Unusual tools ..................................................................................................................25
Table 9: Auxiliary tools..................................................................................................................26
Table 10: Measuring tools.............................................................................................................26
Table 11: Terms and Definitions ...................................................................................................26
Table 12: Tires pressure...............................................................................................................29
Table 13: Approved documents ....................................................................................................30
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Table 14: Conversions..................................................................................................................30
Table 15: Daily pre-flight check list................................................................................................34
Table 16b (a-b): Time limits ..........................................................................................................36
Table 17: Maintenance schedule ..................................................................................................37
Table 18: Main maintenance tasks................................................................................................38
Table 19q (a-q): 50 [hrs] scheduled maintenance .........................................................................54
Table 20b (a-b): 100 [hrs] scheduled maintenance .......................................................................56
Table 21b (a-b): 200 [hrs] scheduled maintenance .......................................................................58
Table 22e (a-e): 1000 [hrs] scheduled maintenance .....................................................................63
Table 23c (a-c): 2000 [hrs] scheduled maintenance......................................................................66
Table 24: Engines.........................................................................................................................79
Table 25. Propellers......................................................................................................................79
Table 26: Fuel system volumes.....................................................................................................82
Table 27: Oil system capacity .......................................................................................................83
Table 28: Cooling system capacity................................................................................................83
Table 29: Battery type...................................................................................................................87
Table 30: Minimum Equipment List...............................................................................................89
Table 31: Standard configuration..................................................................................................90
Table 32d (a-d): Optional configuration, avionics and equipment..................................................94
Table 33: Painting products ..........................................................................................................95
Table 34: Lateral CS push-pull rods dimensions.........................................................................100
Table 35: Longitudinal CS push-pull rod dimension ....................................................................103
Table 36: Directional CS (steering) push-pull rods dimension.....................................................104
Table 37: Trim tab push-pull rods dimension...............................................................................105
Table 38: Engine oil level............................................................................................................108
Table 39: Coolant level ...............................................................................................................109
Table 40d (a-d): Maintenance record table..................................................................................116
Table 41: Service Bulletin performed table..................................................................................117
Table 42: Change or Repair performed.......................................................................................118
0.5. List of Effective Pages
The present Maintenance Manual contains 8 Chapters, 3 Annexes and 132 Pages, all approved by
I.C.P. Srl.
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1. General Information
Each Savannah STM is supplied with a Pilot Operating Handbook, a Maintenance Manual and a
Spare Parts Catalogue; these manuals are considered as parts of the aircraft and they must follow
the aircraft during its entire life.
Maintenance instructions herein described are the only ones approved for a safe maintaining of the
Savannah STM and must be strictly followed.
It’s important to periodically verify that all the airplane manuals version are current, monitoring the
updates on the website of the manufacturer www.icpaviazione.it at My I.C.P. section, by logging in.
If the version is not current, update the manuals. Verify also that the airplane is free from the
application of any new Service Bulletin, or already applied.
For the engine maintenance, ballistic rescue system (if installed) and any other additional equipment
maintenance, refer to relevant manufacturers manuals. The present manual do not show any
equipment information.
WARNING
The owner and finally the pilot should verify that every maintenance
and checks are carried out as prescribed by the manufacturer of each
system, including airframe
WARNING
Any modification to the aircraft that could potentially affect the
structural integrity or flight characteristics that has not been
specifically approved by ICP in written form, will render all
warrantees invalid and absolve ICP and ICP dealers of any further
responsibility to the owner and or operator and liability for the
consequences of such modification. Furthermore, the parts shall be
replaced, for maintenance and repair, with the genuine spare parts
supplied by the ICP Manufacturer or authorized dealers
This manual describes the operations to be carried out for the appropriate inspection, maintenance
and repair of the Savannah STM aircraft. Failure to follow the instruction herein reported will affect
the efficiency of the aircraft and the flight safety.
NOTE
All the maintenance and repair operations should be recorded on the table
at the end of this manual or in a separate Aircraft Maintenance Logbook
WARNING
For complete engine checks and maintenance see the original Rotax
Maintenance Manual and Service Bulletins emitted by B.R.P. Rotax
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CAUTION
Because of the continuous issuing of Service Bulletin and Service
Information byRotax, I.C.P. Srl does not intend toforward such information
to the owners of Rotax engines.
These information are available on the website www.rotax-aircraft-
engines.com in the Technical Documentation page; we also recommend
to contact the authorized Rotax national dealer to receive further
information.
I.C.P. Srl does not take any responsibility for any damage to people and/or
property due to failures in applying Rotax instructions
WARNING
For other equipment checks and maintenance, always refer to the
original approved Maintenance Manual and Service Bulletins issued
by the manufacturer of each relative system (i.e. Propeller, parachute
rescue system). I.C.P. Srl does not take any responsibility for any
damage to people, property and aircraft due to failures in applying
any Service Bulletins, including the ones of the aircraft
WARNING
Inspection and maintenance operations at 1000 and 2000 hours are
particularly delicate; for any doubt, contact the national dealer or the
manufacturer before proceeding
1.1. Meaning of WARNING, CAUTION and NOTE
WARNING
Operating procedures, techniques, etc., which could result in
personal injury or loss of life if not carefully followed
CAUTION
Operating procedures, techniques, etc., which could result in damage to
equipment if not carefully followed
NOTE
Operating procedures, techniques, etc., which is considered essential to
emphasize
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1.2. Technical documentation
The aircraft approved manuals are the following:
- POH-SVNH: Pilot’s Operating Handbook (or Flight Manual) of the Savannah S;
- MM-SVNH: Maintenance Manual of the Savannah S (the present one);
- CM-SVNH: Construction Manual of the Savannah S, kit 1 and kit 2&3 versions;
- SPC-SVNH: Spare Parts Catalogue of the Savannah S;
- Sxxxx: Technical Specification for Savannah S optional installation and description;
- SBxxx: Service Bulletin of ICP (when applicable to Savannah S or specific S/N).
Only the Flight Manual, Maintenance Manual and Spare Parts Catalogue are given with the aircraft,
all the rest of information are present and downloadable from I.C.P. Srl aviation website (www.icp.it)
from My ICP page.
WARNING
Maintain updated all the aircraft documents at the last approved
version present on the I.C.P. Srl website at My ICP page
1.3. Aircraft identification placard
The aircraft is identified by means of Serial Number reported in two different placards: the first one
is located in the right side of the fuselage tail, below the stabilizer; the second is made of stainless
steel and it is attached to the firewall (starting from A/C delivered in 2022).
A generic Serial Number is composed like this:
yy-mm-54-xxxx
Where yy and mm corresponds to the year and month of production, the 54 is the model Savannah
S and the xxxx is the progressive number.
1.4. Authorized personnel
The Owner of the airplane is the only responsible to make disposition for a correct maintenance of
the aircraft and its equipment, by delegating to an approved personnel or organization to carry out
the maintenance work. Any questions regarding the maintenance personnel can be sent directly to
Regarding the equipment installed on the airframe, for example the engine, the propeller or the
parachute, are required different authorized personnel in respect of the airframe, the ones prescribed
in each relative approved Maintenance Manual of the equipment manufacturer. Always refer to the
dedicated manual to find correct information.
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WARNING
A maintenance work on airframe and its equipment carried out by not
authorized personnel, can lead to a safety problems or death
NOTE
Note for S-LSA (USA) airplane: the maintenance of this airplane must be
kept in accordance with the FAA procedures for S-LSA aircraft. Any
maintenance or repair on the airplane must be carried out by a FAA
Certified / Approved Maintainer or Repairman A&P in accordance with
manufacturer maintenance procedure, prescription and Service Bulletin
Certain task of the maintenance herein outlined must be performed by an authorized maintenance
organizations or individuals which have the following conditions:
Task type
Required personnel
Daily pre-flight
Owner of the aircraft or Pilot, where basic knowledge of the aircraft and
experience in this function has been established
50 [hrs] Scheduled
maintenance
Owner of the aircraft only where the National Regulation allows and He
has demonstrated sufficient capacity, knowledge and training to perform
the work. Also, Maintenance Workshop, Individual authorized and
licensed by a National CAA can perform the function or a Person
authorized by I.C.P. Srl where possible
All other Scheduled or
Unscheduled
maintenance, items
with time limits
Starting from the 100 [hrs] / 1 year scheduled maintenance, only
Maintenance workshop or Individual authorized and licensed by a
National CAA and National Dealer of I.C.P. Srl authorized to perform the
function where possible
Major Repairs and
modifications
National Dealer of I.C.P.Srl or Maintenance workshop authorized directly
by the Company to perform each intervention with Its agreement
Engine, Propeller,
Other equipment
Authorized by the equipment manufacturer, as indicated in each
respective Maintenance Manual and/or Maintenance workshop or
Individual authorized and licensed by a National CAA
All the works,
excluding equipment
I.C.P. Srl manufacturer workshop
Table 1: Authorized personnel in function of the maintenance work
1.5. Spare parts purchase
All aircraft structural parts can be purchased only from the manufacturer I.C.P. Srl or the authorized
National Dealer. Equipment like Engine, Propeller, rescue parachute or avionics or consumable
materials can be purchased directly from the manufacturer I.C.P. Srl or alternatively form the
manufacturer of the component itself or from aircrafts parts shop. Any questions can be sent via
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1.6. Warranty
The aircraft warranty expires after 12 months starting from the delivery date to the customer. The
I.C.P. Srl warranty cover the airframe on each part, excluding the equipment installed. Each
equipment is covered by its dedicated warranty politics; always refer to the approved documentation
of the manufacturer to find correct information.
For any request under warranty, contact I.C.P. Srl to the phone address or email at info@icp.it .
1.7. Maintenance Request Form to ICP manufacturer
The request of a scheduled maintenance, extraordinary maintenance or repair to the manufacturer
I.C.P. Srl should be sent via email at [email protected] with attached the module of Request of Technical
Intervention on the Aircraft. At the airplane acceptance in ICP factory workshop, the aircraft must be
accompanied with the Logbook (or Technical Logbook) or the Maintenance Record pages correctly
filled-in and updated to the current state of maintenance of the aircraft. The module of Request is
attached to the present manual and shown in the ANNEX A - Request of Technical Intervention on
the Aircraft.
NOTE
The ICP workshop can not be booked without all the information requested
by the dedicated module shown in ANNEX A - Request of Technical
Intervention on the Aircraft.
An aircraft presented in ICP workshop for maintenance action without the
Logbook and equipment Logbook (i.e. the most important the engine
Logbook) it is not acceptable
1.8. Feedback Form to ICP manufacturer
I.C.P. Srl manufacturer accept a notification of feedback from the owner or maintainer about the
aircraft, its documentation, issues, abnormalities identified during the operation or maintenance. The
feedback should be sent via email at in[email protected] with attached the module of Feedback about ICP
Aircraft. This module is attached to the present manual and shown in the ANNEX B - Feedback
about ICP Aircraft.
NOTE
The ICP Company can not accept a feedback about the Aircraft without an
official email with attached the Feedback Form (previously described) with
all the fields properly filled-in
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1.9. Aircraft protection and anchoring
Savannah STM is an ultra-light metal aircraft almost completely manufactured in Aluminium alloy AL
6061 T6. This AL alloy shows good corrosion resistance features, some simple cleaning operations
are nevertheless required. Backwater should be avoided by through drying after water cleaning.
Furthermore, high pressure water jets should be avoided in order to prevent any infiltrations in points
not easy to inspect or not allowing fast water evaporation.
The original finishing shall remain integer for a long time if the aircraft is periodically washed with a
wet sponge and/or car detergent. Always rinse thoroughly and periodically treat with good quality
nonabrasive wax. If the aircraft is kept in a salty environment, it must be frequently washed with
freshwater and waxed.
Windshield and windows are made of Lexan material, the cleaning should be accomplished with
polycarbonate dedicated products. Lexan in contact with solvent, petrol or any other products with
even a minimum percentage of alcohol should be avoided and could probably damage immediately
or in a short time the part.
The aircraft is not water-proof, rain and humidity can enter from the roof and especially parachute
bridles passage (if installed). In case of in-flight rain, maintain Visual Meteorological Condition and
possibly perform a route going out of shower.
To protect the aircraft, mainly from rain entering in the cabin, cover the wing and fuselage with a thin
water repellent sheet, paying attention to not damage the vortex generators. Before flight open the
door and/or fuselage trap door to eventually dry the water or humidity.
To secure the aircraft in case of outside parking, apply the following procedure:
- set parking brakes on;
- alternatively, set minimum two wheels chokes on nose (or tail) wheel;
- lock the control stick with the safety belt, fully backward;
- in case of strong wind forecast or turbulence, anchor the aircraft with tie down kit, connected
below the wing strut area, to dedicated attachments;
- if required, additionally anchor to ground the tail from the tail skid and the propeller spacer
(not damaging the blades, the spinner, the engine cowling).
The aircraft can be protected also by snow, with the same method above, but a thickness major than
10 [cm] is not allowed and can damage the structure. Remove entirely the snow, remove the cover
and let the structure eventually dry before flight or work on the aircraft.
The best practice of course is protect the aircraft inside of a hangar.
1.10. Aircraft cleaning
The cleaning of the aircraft can be executed with a wet sponge or microfiber cloth or leather and not
with an aggressive/corrosive detergent. The front shield and windows are made of Lexan and the
cleaning must be accomplished with polycarbonate dedicated products, not corrosive, without any
solvent or alcohol. The contact with fuel and oil can damage instantly this material.
MAINTENANCE MANUAL
SAVANNAH S
Doc. No.:
MM-SVNH-EN
Revision:
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Rev. Date:
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Proj. Ref.:
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A/C: Savannah S
Applies to Generic Serial Number: yy-mm-54-xxxx
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WARNING
The contact of any solvent, alcoholic detergent or fuel on the aircraft
windows can damage them permanently creating safety problems
related to cracks, ruptures, visibility, and transparency. in this case,
replace the affected windows
1.11. Consumable materials
Type
Name
Note / Use
Engine oil
AeroShell Oil Sport Plus 4
SAE 10 W-40
According to
Rotax SI-912-016
Engine coolant
Castrol Antifreeze Anti-Boil
According to
Rotax SI-912-016
Brakes oil
Renolit 3000 IT, FIAT Tutela
GI/A
Mineral based oil only
General lubrication
WD-40
General lubrication or
adhesive cleaning
Grease
White grease, Renolit ZT2
Hinges, bushings, bearings,
rotating parts
Spray grease
Bardahl High speed chain
Rotating parts, general
additional lubrication
Anti-seize
Copper based anti-seize paste
CFG
Landing gear spring fixing
bolt-nut
Thread locker
Blue Loctite 243
* see below possible positions
Fuel fitting sealant
Yellow Loctite 577
Seals fuel fittings on tank or
junction
Verification green marks
Green Paint Marker
Manufacturer production
verifications of bolted
connections
Bolt-nut cross-check marks
Cross-check red torque seal
Engine and equipment cross-
check bolt-nut marks or other
relevant coupling
Note: * possible positions of thread locker: nose landing gear leg, upper plate bolts; brake disc supports; brake
caliper inner bolts; bolts on anchor nuts of the front spar fin attachment; parachute and rocket M6 attachments;
parachute carabiners; engine hosing to inner mount attachments M10; electric fuel pump attachment bolts; 3
bolts of the wing fuel cup plastic cover on ring; cabin/carburettor heating knob on bowden thread; door gas-
spring attachment bolts; fuel tank M6 connection/support bolts
Table 2: Consumable materials
MAINTENANCE MANUAL
SAVANNAH S
Doc. No.:
MM-SVNH-EN
Revision:
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Rev. Date:
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Proj. Ref.:
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A/C: Savannah S
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1.12. Nominal diameters
Item
Diameter [mm]
Tolerance [mm]
3.2mm rivet hole
3.2
0.2
4mm rivet hole
4
0.2
M4 riv-nut hole
6
0.2
AN3 bolt
3/16’’=4.8
N/A
AN4 bolt
4/16’’=6.4
N/A
AN5 bolt
5/16’’=7.9
N/A
AN6 bolt
6/16’’=9.5
N/A
AN3 hole
4.9
-0.1/+0.2
AN4 hole
6.5
-0.1/+0.3
AN5 hole
8.0
-0.1/+0.3
AN6 hole
9.6
-0.1/+0.3
Flight Control Surfaces hinge line, bushing internal
diameter
4.9
0.1
FCS hinge line, bushing external diameter
5.9
+/-0.1
FCS hinge line, horn hole for bushing
6.0
0.2
Table 3: Nominal diameters
1.13. Tightening torques
Standard application
Screw size
Torque [Nm]
Tolerance [Nm]
AN3
6
+/-0.5
AN4
15
+/-1
AN5
20
+/-1.5
AN6
30
+/-2
AN7
45
+/-2
AN8
65
+/-2
M5
6
+/-0.5
M6
13
+/-1
M8
25
+/-1.5
M10
40
+/-2
Table 4: Tightening torques for standard application
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Doc. No.:
MM-SVNH-EN
Revision:
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Rev. Date:
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Proj. Ref.:
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A/C: Savannah S
Applies to Generic Serial Number: yy-mm-54-xxxx
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Unusual application
Part
Screw id
Torque [Nm]
Tolerance [Nm]
Upper fork of the rear wing strut
(rear strut assembly)
AN4
6.5
+0/-0.5
Flight control system bolt
crossing the uniball
AN5
16
+/-0.5
Flight control system uniball nut
on rod
M8
10
+5/-0
Trim tab uniball crossing bolt
AN3
6
+/-0.5
Trim tab uniball counter-nut on
rod
M5
6
+/-0.5
Trim tab actuator lever
connection to uniball and rod
M3
Touching + as
required
Prevent damage
of actuator lever
Flight control system self-locking
nut joints (not rotating bolt)
AN3
6
Allows rotation
without axial and
radial free play
Flight control system castle nut
joints
AN3 / AN4 / AN5
Touching - as
required for teeth
alignment for pin
Allows rotation
without axial and
radial free play
Flight control surfaces hinges
AN3
Touching - as
required for teeth
alignment for pin
Allows rotation
without axial and
radial free play
Nonio tender bolt
AN3
6
+/-0.5
Pulley axis bolt
AN3
Touching - as
required for teeth
alignment for pin
Allows rotation
without axial and
radial free play
Torque tube rear horn (roll)
AN3
Touching + as
required to lock
Prevent tube
ovalization
Flaperon mixer horns (roll)
AN3
Touching + as
required to lock
Prevent tube
ovalization
Flaperon mixer hinges
AN5
Touching
Allows rotation
Rudder pedals plastic hinges
bushing
AN3
Touching + as
required to allows
pedals rotation
Not excessive
friction in the
pedals rotation
Spacer to engine flange
M8
25
+/-1.5
Wheel hub bearing ring nut
M17
Close up to the
wheel is not easily
rotating by hand
Not excessive
friction to the
wheel rotation
Main wheel hub axle ring nut
M24
60
+10/-0
Nose wheel hub axle ring nut
M17
Close up to the
wheel is not easily
rotating by hand
Not excessive
friction to the
wheel rotation
Wheel rim assembly
(ICP production)
AN4
15
+/-1
Wheel rim assembly
M8
15
+/-1
Table 5a
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Rev. Date:
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Proj. Ref.:
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A/C: Savannah S
Applies to Generic Serial Number: yy-mm-54-xxxx
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Unusual application
Part
Screw id
Torque [Nm]
Tolerance [Nm]
Wheel disc supports on rim
M5
8
+2/-0
Wheel disc
M6
10
+2/-0
Main landing gear spring lower
constrain flange, vertical
attachment bolts / stop nuts
M8
Close up to the
spring is
completely
constrained in the
channel against
red vulcolan rubber
Not excessive,
prevent nut and
fuselage damage,
not more than 20
[Nm]
Nose wheel hub bolt on fork
(round head, hexagonal wrench)
M8
20
+/-1.5
For Tail Dragger configuration (if
applicable), front horn to
connect the steering pedal rods,
torque of bushing
AN4
Touching
Not excessive
friction, the horn
can rotate
Brake caliper outer bolts/nuts
M6
15
+/-1
Brake caliper inner bolts
M6
10
+/-1
Engine mount internal ring on
engine housing
M10
40
+/-2
Engine mount silent block
AN5
20
+/-1.5
Fuel metal clamp
N/A
Maximum possible
screw closure
Not excessive,
prevent hose
cutting
Fuel shut-off valve fittings
N/A
Touching + 1/4 turn
Not excessive,
prevent only fuel
loosing
Tank fitting and drain valve 1/4’’
N/A
Touching + 1/4 turn
Not excessive,
prevent only fuel
loosing
Collector tank reserve probe
M16
N/A
Touching + 1/4 turn
Not excessive,
prevent only fuel
loosing
Tank anchoring points
M6
8
+2/-1
Oil line metal clamp
N/A
Maximum possible
screw closure
Not excessive,
prevent hose
cutting
Fitting on oil tank
N/A
25
+0/-2
Drain screw of oil tank
M12
25
+0/-2
Fitting on oil radiator
N/A
20
+5/-0
Engine oil pump fittings
M18
25
+/-1.5
Engine crankcase oil banjo bolt
M6
10
+/-0.5
Magnetic plug
N/A
25
+0/-2
Engine oil filter
N/A
Touching +3/4 turn
N/A
Engine water pump bolts
M6
10
+/-0.5
Table 5b
MAINTENANCE MANUAL
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Doc. No.:
MM-SVNH-EN
Revision:
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Rev. Date:
07/11/2022
Proj. Ref.:
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A/C: Savannah S
Applies to Generic Serial Number: yy-mm-54-xxxx
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Unusual application
Part
Screw id
Torque [Nm]
Tolerance [Nm]
Cooling line metal clamp
N/A
Maximum possible
screw closure
Not excessive,
prevent hose
cutting
Radiators supports
M10
30
+10/-5
Radiators silent block
M6
13
+/-1
Airbox supports
M6
13
+/-1
Metal clamp fuel system
N/A
Maximum possible
screw closure
Not excessive,
prevent hose
cutting
Metal clamp (general)
N/A
Strong screw
closure
Fix the pipe,
prevent hose
excessive
compression
Norma metal clamp
M6
Surfaces of clamp
touching or if
possible 13
Prevent
compression of
inner pipe
Terminals for engine electric
wirings (starter motor, starter
relay)
M6
4
+1/-0
Exhaust collectors on cylinder
(bent flange)
M8
15
Attention, leave a
minimum of 1
screw thread free
after the nut
Exhaust terminal collar
N/A
Max possible
closure
N/A
Table 5c (a-c): Tightening torques for unusual application
1.14. Safetying practices
Any time a self-locking nut and/or split pin is removed for inspection, such part(s) should be replaced
with a spare new one before reassembling.
1.14.1. Safety wires
Install the safety wire tight in sense of preventing the unscrewing rotation of the nut or element. The
safety wire is considered correctly installed if it is really tight and all the parts with double wire are
turned constantly.
MAINTENANCE MANUAL
SAVANNAH S
Doc. No.:
MM-SVNH-EN
Revision:
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Rev. Date:
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Proj. Ref.:
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A/C: Savannah S
Applies to Generic Serial Number: yy-mm-54-xxxx
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Figure 1: Safety wires example
Always replace the safety wire with a new one, when the bolt or nut has been opened.
1.14.2. Castle nut and cotter pin
There are two different method to install the cotter pin on the castle nut (Figure 2): the first one with
cotter pin oriented verticallyand the other one horizontally in respect of the nut cutting. In both cases,
the cotter pin is considered properly installed if it is tight, not moving, the loop is not deformed and
constrained. The free edges of the pin must touch the bolt, constrain the pin itself and not touch the
surrounding structure. In case of vertical pin orientation, the loop is within the nut cutting, instead the
horizontal pin orientation must have the loop outside the castle nut cutting.
Figure 2: Cotter pin example
Always replace the cotter pin with a new one, when the bolt or nut has been opened.
The cotter pin size must be correctly coupled with the castle nut, as shown in the Table 6 below.
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