Safety Alert
ZLIN Savage Cub · Service Bulletins
Overview
This document is a Safety Alert issued by Zlin Aviation regarding the Zlin Savage Cub aircraft. It addresses potential corrosion issues in the rudder cables and provides guidance on inspection and maintenance procedures to ensure continued airworthiness.
- Safety Alert issued on 30 October 2012.
- Applies to all Savage Planes and models.
- Inspect for corrosion on stainless steel wires used for control surfaces.
- Daily pre-flight checks of rudder cables are crucial.
- Corrosion was found in a 9-year-old Savage Cub with 780 flying hours.
- Replace any worn cables immediately before the next flight.
- Old airplanes must verify application of Safety Alert Nº1.
- Contact Zlin Aviation for replacement wire sets if needed.
Document
Source
Originally published by zlinaero.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type ·
- Service Bulletins
- Year ·
- 2019
- File size ·
- 1.7 MB
- Publisher ·
- zlinaero.com
- Language ·
- en
Specifications & performance
Extracted from this document.
Specifications
- Flying hours ·
- 780
- Cable diameter mm ·
- 3
What is the Safety Alert?
The Safety Alert is a service bulletins for the ZLIN Savage Cub, dated 2019.
Where does the Safety Alert come from?
This copy of the Safety Alert was originally published by zlinaero.com and is hosted on Sprinkle as a free, searchable reference copy.
What year was the Safety Alert published?
The Safety Alert — the ZLIN Savage Cub service bulletins on file — is dated 2019.
Most owners only have the POH. Here's the essential set for the ZLIN Savage Cub.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins on file
- Type Certificate (TCDS)
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In this document
Airplanes Affected
All Savage Planes and models.
Reason for Alert
Corrosion found on stainless steel wires used for ailerons, rudder, and stabilizers.
Inspection Procedure
Inspect cables for corrosion, remove heat shrink tubes, and seal sleeves with Tesa tape if no defects are found.
Maintenance Manual Reference
Daily checks of rudder cables are specified in the Maintenance Manual.
Accomplishment Steps
Perform a complete check of cables and ensure compliance with previous safety alerts.
Contact Information
For replacement wires/cables, contact Zlin Aviation directly.
Safety notes
- Perform daily checks on rudder cables.
- Inspect for corrosion, especially in corrosive environments.
- Replace any worn cables immediately.
- Ensure compliance with Safety Alert Nº1 for older aircraft.
- Seal sleeves properly to prevent corrosion.
Full document text
Document Continued Airworthiness – Service Publications – Safety Alert Zlin Aviation S.R.O. 2. Kvetna 685 763 61 Napajedla Czech Republic Safety Alert 30 October 2012 • Airplanes affected: d models • Subject: on the pedals from the instructor to correct an action of the • Compliance: Issue date of SA 1) In December 2006 Zlin Aviation sro issued already the Safety Alert nº1, motivated from the detection of a premature rudder cable consumption: alert was instructing about changing the cables to a bigger section (3mm AISI 316 stainless steel, as actually in use), and the pulleys to a new type of phenolic material (as actually in use). The company at that time has provided upgrade kits to customers. 2) Section of cables and complete cable installation has undergone stringent load tests and has proven to perfectly withstand all safety margins required by several certification bodies in different countries. In fact, the size of the cable and related components follows industry standards, is over 20.08.2019 QAP-CA-SP-SA-09 All Savage Planes and models • Reason: No 09 20.08.2019 Visual check for possible sleeves corrosion on all stainless steel wires used for ailerons, rudder, stabilizers (*) flaps controls (*). (*) not for Shock Cub and Shock Ultra A 9 years old Savage Cub with 780 flying logged hours, always hangared and operated in proximity of the sea and so in a particular corrosive environment was checked by the owner after he noted an anomalous swelling all around the sleeves area. The black heat shrinkable tube placed during the wire assembling over the sleeves, didn’t allow to notice immediately the reason of the swelling so the owner decided to cut and remove the black seal, finally founding the reason of the swelling. The attached pictures show the occurred problem and how to work on it. A deep corrosion was finally reported. Zlin Aviation sro © 2019 Page 1 of 3 servicereports@zlinaero.com www.zlinaero.com Document Continued Airworthiness – Service Publications – Safety Alert engineered for the actual purpose, and a failure was never before reported. 3) IMPORTANT: The Maintenance Manual specifies that the complete check of the conditions of the rudder cables has to be performed in the daily pre flight checks. We strongly encourage to give importance to your pre-flight check and to apply pressure to the pedals in order to move it and to see the conditions of the cables underneath the pulleys, where they k also for proper tension and alignment between cable and pulleys. 4) Circumstances of this incident: it is our official opinion, and the e pilot pressure, for correcting a wrong pilot input, together with a pre-existent wear of the cable that was not detected during the flying take offs and landings at the time of that episode), lead to this failure. The second cable, not broken, shows wear in the same place were the failure happened on the opposite side cable, right were the cable goes around the small pulley. 5) We do not consider that a failure of that type can happen, if daily checks confirm the good condition of the cables and pulleys. Load tests, calculations, and very long service experience back up our sentence. For that reason we do not consider necessary to issue any technical upgrade at this point. We invite pilots and operators however, to give importance to those checks, particularly in case they know that for the activity they do (many hours of flight training for example), a premature wear can take place in comparison to low use private sport airplanes. If any minor wear in the cable appears, it must be substituted for a new one. • Accomplishment: -Perform a complete check as described in point 3 of the foreword. For old airplane produced before 2006, double check that Safety Alert Nº1 has been applied and cable is 3mm thick. QAP-CA-SP-SA-09 Step 3: Step 4: For new sets of replacement contact us directly and we will dispatch new sets of wires/cables for each customer affected by this issue Steps to be done: First of all , you need to decide if it is better to remove all the wires , for some it might be impossible to do so. It can also be done inside the fuselage with no bigger issues . Step 1: Step 2: Check for any corrosion or other issues like degradation of the sure , send us some pictures for assessment Pictures of issue occured: If all sleeves are good with no corrosion on them or any other defects are found , you can seal the sleeves with Tesa tape used for wiring looms (or any other duck tape that suits the needs) If any corrosion or any other issues are found on the wires Remove all heat shrink tubes from sleeves so you can see the condition of the sleeves Zlin Aviation sro © 2019 Page 2 of 3 sleeves due to high salt concentration in the air . If you are not it is mandatory to replace them all immediately before next flight. servicereports@zlinaero.com www.zlinaero.com This step applies only when corrosion or any other defects are found. Document Continued Airworthiness – Service Publications – Safety Alert Picture: 1) Important check points for evaluating the conditions of the cable. Move the rudder or pedals in order to see the cable Check also the condition of the rudder cables in the tail section. QAP-CA-SP-SA-09 Inspection procedure : Hold the wire Cut the shrinkable tube Remove the tube Inspect the sleeves Seal the sleeves with the Tesa tape Use small amount of heat to seal it Zlin Aviation sro © 2019 Page 3 of 3 servicereports@zlinaero.com www.zlinaero.com