ICP Savannah VG User manual

I.C.P. Srl
Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
Page 1
Issue 1/Revision 04
ICP Srl –S.P.16 km 15,150-14022 Castelnuovo Don Bosco (AT)
August 2011
Phone [phone] •Fax [phone]
MAINTENANCE MANUAL
Savannah™VG / XL VG
Copyright I.C.P. 2002
Savannah™ is registered trademark solely owned by ICP srl and their use in any form is strictly
forbidden.
The content of the present manual is the sole property of I.C.P. srl and cannot be reproduced by
third parties in any form whatsoever without ICP’s previous written authorization.

I.C.P. Srl
Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
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Issue 1/Revision 04
ICP Srl –S.P.16 km 15,150-14022 Castelnuovo Don Bosco (AT)
August 2011
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LOG OF REVISIONS
Revision
Number
Revised
Pages
Description of Revision
Date
00
All
First version
06/06
01
All
Effective also for XL
11/08
02
11
Point 34, general change.
5/2/2009
03
16
1000h/1500h
27/2/2009
TABLE OF CONTENTS

I.C.P. Srl
Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
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ICP Srl –S.P.16 km 15,150-14022 Castelnuovo Don Bosco (AT)
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SECTION 1
INSPECTION SCHEDULE AND REPORTS
Paragraph
Page
1.1
Inspection schedule
4
1.2
Maintenance historic report
5
1.3
Inspection reports
6
1.3.1
Daily/pre-flight inspection
8
1.3.2
25 hours inspection
9
1.3.3
50 hours inspection
12
1.3.4
100 hours inspection
13
1.3.5
200 hours inspection
15
1.3.6
600 hours inspection
16
1.3.7
1000 hours inspection (Aircraft overhaul)
16
1.3.8
1500 hours inspection (Engine overhaul)
16
1.3.9
Consumer material
17

I.C.P. Srl
Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
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ICP Srl –S.P.16 km 15,150-14022 Castelnuovo Don Bosco (AT)
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1.1 INSPECTION SCHEDULE
The aircraft’s maintenance schedule is as indicated in the table below:
Daily/Pre-flight inspection
before the first flight each day
25 hours inspection/3 months
every 25 hours flight time/ 3 months
50 hours inspection
every 50 hours flight time
100 hours/12 months inspection
every 100 hours flight time/12 months calendar
time
200 hours/18 months inspection
every 200 hours flight time/18 months calendar
time
600 hours
every 600 hours flight time
1000 hours flight time/72 months
every 1000 hours flight time/72 months calendar
time
1500 hours inspection (Engine overhaul)
every 1.500 hours flight time
1.2 MAINTENANCE HISTORIC REPORT

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
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Sc. flight time
Sc. cal. time
Total time
Date
Location
Mechanic
25
3 m
50
75
100
12 m
125
150
175
200
18 m
225
250
275
300
24 m
325
350
375
400
30 m
425
450
475
500
36 m
525
550
575
600
42 m
625
650
675
700
48 m
725
750
775
800
54 m
825
850
875
900
60 m
925
950
975
1.000
64 m
1.025
1.050
1.075
1.100
68 m
1.125
1.150
1.175
1.200
72 m

I.C.P. Srl
Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
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ICP Srl –S.P.16 km 15,150-14022 Castelnuovo Don Bosco (AT)
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Sc. flight time
Sc. cal. time
Total time
Date
Location
Mechanic
1225
1250
1275
1300
78m
1325
1350
1375
1400
84m
1425
1450
1475
1500
90m
1.3 INSPECTION REPORTS

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
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ICP Srl –S.P.16 km 15,150-14022 Castelnuovo Don Bosco (AT)
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NOTE:
Below are indicated the exact meaning of all the terms used in the inspection reports in order to
avoid any possible misunderstanding.
Visual inspection
Inspection to be performed without using any instrument or testing device,
by expert and trained eye only.
Functional inspection
Inspection to be performed by supplying the component to be inspected
with the proper energy, in order to check its correct operativeness, without
removing the component from the aircraft.
Test
It’s a verification of a component, without disembarking it from the
aircraft, to be performed by using a tester or other suitable instrumentation,
to check its proper operation.
Check
It’s a verification, typically to be performed by the pilot, without removing
anything from the aircraft, to determine whether there is a correct cause-
effect relation produced by engaging the device to be checked.
Bench test
It’s a verification of a component, disembarked from the aircraft, to be
performed by connecting it to a testing bench or other laboratory suitable
instrumentation, to check its proper operation and measure some significant
parameters values.

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
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1.3.1 DAILY/PRE-FLIGHT INSPECTION
N.
DESCRIPTION
MECH.
CER. ST.
1
Without moving the aircraft, drain the airplane fuel system
2
Check all the airplane surfaces to assure there’s no noticeable
defects or any accumulation of slush, snow or other detrimental
material.
3
Remove all the mooring ropes and the gust lock devices.
4
Check there aren’t any defects in the windshield or windows.
5
Check the landing gear for no defects, no damaged tires, and tires
for proper inflation.
6
Check all the fairings and inspection panels for general condition,
safety and no loosen or missing fastener.
IMPORTANT: Your airplane is made with aeronautic alluminium (6061 T6) with good
anticorrosion characteristics, but however simple cleaning procedures are always necessary. It is
important to avoid water stagnation making appropriate drying. Don’t use pressure jet of water to
avoid infiltration into not accesible point.
The original finishing will remain for a long period, if periodically the airplane is washed with a
wet sponge and a car detersive. Rinse always with a lot of water.
Periodically, use a good not abrasive car wax.
If the airplain lies in an saltish ambient, (near the sea) it must be washed frequently with fresh
water; repeat treatment with a good not abrasive car wax.
IMPORTANT: due to continuous emission of Service Bullettins and Service Informations by Rotax,
I.C.P. Srl does not intend to transmit anymore those informations to Rotax engines owners. Those
informations are available on web site www.rotax-aircraft-engines.com in section
"Documentation": we also suggest to contact the official Rotax dealer in your country.
I.C.P. Srl does not take any responsability of eventual damage to persons and things due to lack of
application of Rotax prescriptions.

I.C.P. Srl
Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
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1.3.2 25 HOURS/ 3 MONTHS INSPECTION
N.
DESCRIPTION
MECH.
CER. ST.
1
Remove all the engine fairings
2
Open the inspection panel on the bottom of the fuselage
3
Check the general conditions of the whole airframe
4
Check the propeller for dents and cracks; check the blades leading
edge protection for condition;
NOTE: if some vibrations are noted the prop should be balanced
5
Check for presence and integrity of the safety nuts or the safety
wire on the propeller’s hub
6
Check the battery for proper liquid level, drain pipe condition,
corrosion due to acid spills and for electrodes condition
7
Check the flight controls for freedom of movement, excessive
play; all screws and nuts must be in place, properly tightened and
fitted with their safety devices
8
Check the flight controls cables, their end fittings and the
nicopresses; to check out for broken wires in cable, touch it along
by hand and by a soft fabric piece; if required, replace the cable
with an original spare
9
Check the pulleys and the teflon guides
10
Lubricate all the moving parts
11
Check all the components for freedom of movement and
excessive play
12
Check the flight controls cables tension; the proper tension is 18-
24 lbs (9-12 kg); greater tension induce too high load on the
aircraft’s structure and make the flight controls too hard to
operate, lower tension induce a very imprecise and not ready
response; at the worst, some flutter at the moving surfaces may
arise; the too low tension cables ARE VERY DANGEROUS
12e
Check throttle lever on firewall and in particular the welding on
the 4 levers
13
Check the radiator is fully accessible by the cooling air and the
duct isn’t obstructed by grass, leaves or other debris; check for
coolant leaks, all the hoses and clamps are in place and properly
secured
14
Parachute: if installed, check for security, bridles condition, that

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
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the hook is locked, the control cable for condition
15
Check the electric wires for condition, routing and security; check
the anti-collision lights control box for condition, if installed
16
Check the flaperon and elevator springs for security; adjust if
required
17
Visually inspect the fuselage interior; close the inspection panel at
the fuselage bottom
18
Check the landing gear for general condition; check the wheel
fairings if installed, the tires for wear and proper pressure
19
Check and, if required, adjust the brake control
20
Check the nose gear elastic chord and the sliding strut for excess
of play, clean and lubricate properly
21
Check the pedal rods and rod-ends; clean and lubricate properly
NB
WARNING: following a hard landing, particularly if happened in
a crosswind situation, check the wheel fork alignment.
22
Check all the bolts, nuts and attachment connections of the wings:
all the safety locking devices should be in place and not broken
23
Check the flaperon hinges: they should be show freedom of
movement and no play and be fitted with the safety locks
24
Clean all the flaperon hinges and lubricate
25
Check all the empennages hinges for freedom of movement and
no play, clean and lubricate; Check the cable end attachment
fittings for condition, freedom of movement, no play, cleanliness
and lubrication
26
Inspect for condition and security the four (4) horizontal tailplane
to fuselage attachment connections
27
Check all the inspection panels for condition and security, their
hinges and fasteners; clean and lubricate properly
28
Inside the cabin check for general condition, open the control
stick repair, check all hinges, screws, nuts, safety locks, for
freedom of movement, excessive play
29
Lubricate the control stick mechanism (3 spots)
30
Close the control stick repair; make sure to fix it.
31
Visually inspect the cabin electrical system, the brake system’s
pipes and cables, the cabin switches, breakers, all controls
32
Lubricate the brake system cables and the rudder pedals
33
Clean all inside the cabin
NB
NOTE: to properly maintain the engine it’s strongly
recommended to follow the engine manufacturer instructions
and all Rotax service informations
34
Fuel system: visually inspect pipes, clamps, fuel filter, electric
pump and mechanical pump; clean and inspect float chambers and

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
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replace fuel filter if necessary.
35
Check and lubricate throttle and mixture cables and linkages; if
required, adjust engine idle and idle carburation
36
Check the air hoses and air filters condition
37
Lubrication system: check for condition all pipes and clamps;
check for the proper oil level, refill if required
38
Cooling system: check for condition all pipes and clamps, coolant
level and coolant level in the coolant recovery reservoir, check all
cooling system components are properly secured
39
Engine electrical system, ignition system: check for general
condition, properly fastened electrical connections, no damaged
wires, no connections oxidation, etc.; check the ignition harnesses
be properly connected to the spark plugs
40
Spark plugs cleaning; re-gap or replace as required
41
By using a suitable tester (differential pressure gauge) check the
engine compression
42
Check the engine silent-blocks, the engine and engine mount
attachments
43
Check the exhaust system for cracks, loose fasteners, springs in
place and oxidation
44
Thoroughly clean both the engine and its accessories
45
Check for condition of the air-box support spring

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
01-12-51-122
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August 2011
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1.3.3 50 HOURS INSPECTION
NOTE: The 50 hours inspection requires that a 25 hours inspection is carried out plus the checks
below stated.
N.
DESCRIPTION
MECH.
CER. ST.
1
Check out all the movable surfaces’ deflection angles; make
reference to the attached drawing
2
Check the nose landing gear wheel and vertical tailplane
alignment
3
Check the brakes operating effectiveness; clean or replace the
pads as required
4
Change oil filter
5
Change oil with recommended type

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Savannah™ VG - XL VG AIRPLANE
MAINTENANCEMANUAL
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1.3.4 100 HOURS/12 MONTHS INSPECTION
NOTE: The 100 hours/12 months inspection requires that a 50 hours inspection (25 hours plus the
50 hours adding checks) is carried out plus the checks below stated.
N.
DESCRIPTION
MECH.
CER. ST.
1
Thoroughly check the nose landing gear steering and shock
absorbing systems; recover excessive plays as required
2
Thoroughly inspect the firewall for corrosion, cracks, security and
general condition
3
Fuselage: carefully inspect the fuselage interior and exterior for
loose rivets, unproperly tightened bolts, corrosion and panel
deformations which can be caused by excessive dynamic loads or
hits
4
Flight controls: check for excessive play, weared components,
attachment fittings for condition
5
Check the movable surfaces travel stops
6
Check the flaperon attachment fittings
7
Wings and wing struts: thoroughly check the wing skin for loose
rivets, corrosion, panels deformation and damage, inspect the
wing leading and trailing edges; check all the bolts and safety
locks
8
Empennages: thoroughly the empennages skin for loose rivets,
corrosion, panels deformation and damage, inspect the
empennages leading and trailing edges; check all the bolts and
safety locks
9
Drain and refill the engine oil
10
Replace the oil filter
11
Check fuel main valve functionality:
•Brake air plane with the wedge and with brake pedals
•Start engine (3000 RPM) and close the fuel main valve (take
out safety wire); wait until engine stop
Open the fuel main valve and make again the safety wire.
NB
NOTE: the maximum allowed play in the flight controls system
hinges is 0,6 mm; when a greater play is found, please contact the
manufacturer
NOTE: before replace a loose or a corroded rivet, please contact
the manufacturer
NOTE: if a skin panel crack is found, before next fly, please
contact the manufacturer
N.
DESCRIPTION
MECH.
CER. ST.

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MAINTENANCEMANUAL
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NOTE: in the event of a hit on the wing leading edge, it has to be
understood they don’t reduce the wing structural resistance until
they become more than 15 mm long over each 1 m wing span;
they could slightly affect the in-flight aircraft’s trimming;
periodically check for a crack that could arise

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MAINTENANCEMANUAL
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1.3.5 200 HOURS/18 MONTHS INSPECTION
NOTE: The 200 hours/18 months inspection requires that a 100 hours inspection (25 hours plus the
50 hours adding checks, plus the 100 hours adding checks) is carried out plus the checks below
stated.
N.
DESCRIPTION
MECH.
CER. ST.
1
Check the fuel pipes, replace the fuel filter and the gascolator
valve gasket
2
Drain and refill the coolant fluid in the cooling system
3
Replace the spark plugs
4
Remove, clean and reinstall the oil reservoir
5
Check carefully the silencer

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MAINTENANCEMANUAL
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1.3.6 600 HOURS INSPECTION
NOTE: that inspection requires some mid-life engine checks ONLY be carried out as per the
following table:
N.
DESCRIPTION
MECH.
CER. ST.
1
Check the carburettors’ valve play; the valve must be replaced if
the play exceeds 0.5 mm)
2
Check the friction, if installed
1.3.7 1.000 HOURS/72 MONTHS INSPECTION (AIRCRAFT OVERHAUL)
NOTE: The 1000 hours/72 months inspection reqires that a 200 hours inspection (25 hours plus the
50 hours adding checks, plus the 100 hours adding checks, plus the 200 hours adding checks) is
carried out plus the checks AND REPLACEMENTS below started. The aircraft overhaul must be
carried out by the manifacturer or by a specifically approved maintenance facility.
N.
DESCRIPTION
MECH.
CER. ST.
1
Replace all tubes of fuel system
2
Replace all tubes of lubrication system
3
Replace all tubes of cooling system
4
Replace the rubber sleeves
5
Replace propeller’s bolts and nuts
6
Replace accelerator’s cables
7
Replace engine’s silent blocks and nuts and bolts
8
Replace rubber band and inferior guides
9
Replace the bearings of three wheels and anterior wheel pin
10
Replace rubber elastic elements of leaf spring
11
Replace the bushing of command line and all nuts and bolts
12
Replace the connect bushing of all planes (aileron, flap, elevator,
rudder)
13
Dismantle the wings and check the ovalization of hole (max 0,5
mm). Replace all nuts and bolts
14
Dismantle all tailplane and check ovalization of hole (0,5 mm).
Replace all nuts and bolts
15
Replace SD023, SD024 and SD025
16
If not present, install wings connection’s trapdoors and upgrade of
wings connections and bolts and wings connections
1.3.8 1.500 HOURS INSPECTION (ENGINE OVERHAUL)
NOTE: the engine overhaul must be carried out by the engine manufacturer only. In this case
replace the Aluminium engine support.

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MAINTENANCEMANUAL
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1.3.9. CONSUMER MATERIAL
- Engine oil: Multigrade oil according to API classification(API
SG or JASO MA). Castrol GPS
- Cooling liquid: Castrol Long Life Coolant
Attention: use EVANS NPG+ if showed on the
label on the liquid bottle
- Brake liquid: MINERAR BASIS OIL FOR HIDRAULIC USE (DO
NOT USE SINTETIC OIL TYPE DOT4).
- Plug: NGK DCPR7E (Rotax 912 UL)
NGK DCPR8E (Rotax 912 ULS)
The content of the present manual is the sole property of I.C.P. srl and cannot be reproduced by
third parties in any form whatsoever without ICP’s previous written authorization.
Copyright I.C.P.2002