Aeropro CZ A220 Maintenance Manual Download | Manualshive

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Maintenance Manual

AEROPRO CZ

Maintenance Manual

March 21, 2020

Brakes Fail to Operate

Leak in system.

Install new parts.

Air in system.

Bleed system.

Lack of fluid in master cylinder.

Fill and bleed system.

Master cylinder defective.

Install a new cylinder.

5.24 Brake master cylinders

(refer to figure 5-4.)

The brake master cylinder, located on the pedals, is activated by gently pushing on the brake

pedals positioned on the cockpit floor. A small reservoir is incorporated onto the master cylinder for
the fluid supply.

Figure 5-4 - shown are old brake cylinders - A220's since 2009 have red Beringer brake cylinders

note: photo above is showing older brake system - see separate information regarding the

Beringer brake cylinders and the brake fluid reservoir in 2009 and newer A220's

note: photo above does NOT show the rudder-centering system and rudder trim
adjustment system on all Aeropro aircraft starting in 2012 - see Section 9 for information

1.  brake pedal on the right side
2.  brake pedal on the right side
3.  brake pedal on the left side
4.  brake pedal on the left side
5.  master cylinder with fluid reservoir for right wheel
6.  master cylinder with fluid reservoir for left wheel
7.  master cylinder for right wheel
8.  master cylinder for left wheel
9.  hydraulic tube for connection master cylinder and brake

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Summary of Contents for CZ A220

Page 1: ...opro CZ A240 A220 MAINTENANCE MANUAL Aeropro CZ A240 A220 MAINTENANCE MANUAL standard with Rotax 912ULS engine also with section for A220 taildragger and with section for optional Rotax 914UL turbo engine ...

Page 2: ... 1 thru 3 9 0 4 1 thru 4 8 0 5 1 thru 5 12 0 6 1 thru 6 7 0 7 1 thru 7 4 0 8 1 thru 8 4 0 9 1 thru 9 3 0 10 1 thru 10 23 for 912ULS engine 0 10a 1 thru 10a 13 for 914UL turbo engine 0 11 1 thru 11 6 for 912ULS engine 0 11a 0 thru 11a 5 for 914UL turbo engine 0 12 1 thru 12 2 0 13 1 thru 13 3 0 14 1 thru 14 8 0 15 1 thru 15 9 0 16 1 thru 16 1 0 17 1 thru 17 1 0 18 1 thru 18 1 0 19 1 thru 19 2 0 20 ...

Page 3: ...or control system 7 1 8 Structures Elevator trim control system 8 1 9 Structures Rudder control system 9 1 10 Engine standard Rotax 912ULS 10 1 10A Engine optional Rotax 914UL turbo 10a 1 11 Fuel system standard Rotax 912ULS 11 1 11A Fuel system optional Rotax 914UL turbo 11a 0 12 Propeller 12 1 13 Utility systems 13 1 14 Instruments and instrument system 14 1 15 Electrical systems 15 1 16 Structu...

Page 4: ...hanic to maintain the Aeropro CZ A240 A220 aircraft and thereby establish a reputation for reliable service All information contained is based on data available at the time of publication and is supplemented and kept current by service bulletins published by the Aeropro CZ Company These bulletins are sent to all Aeropro Aircraft Dealers so that they have the latest authoritative recommendations fo...

Page 5: ...cu in 1 cu in 16 3871 cm 3 1 gal US 3 7854 l dm 3 Units of mass 1 kg 2 2046 lb 1 lb 0 45359 kg Units of force 1 N 0 224809 lbf 1 lbf 4 4482 N Units of pressure 1 bar 1000 hPa 1 bar 14 5037 lbf in2 psi 1 lbf in2 psi 0 0689 bar 1 in HG 33 8638 hPa Units of temperature C F 32 1 8 F C x 1 8 32 Velocities 1 m s 3 6 kph 1 ft min 18 288 m s 1 m s 0 0555 ft min 1 kts 1 852 kph 1 kph 0 53996 kts Torques 1 ...

Page 6: ...acement parts 1 7 1 11 General safety information 1 8 1 12 Reporting possible safety of flight concerns during inspection 1 8 1 1 General description 1 2 Description The Aeropro aircraft as described in this manual are conventional high wing aircraft The main supporting structure of the fuselage is of lattice work welded of steel tubes The A240 aircraft is a fixed tricycle landing gear with a stee...

Page 7: ...s manual except where other values are stated They are not to be used for checking tightness of installed parts during service Figure 1 2 M4 4 Nm 35 in lb M5 6 Nm 53 in lb M6 10 Nm 88 in lb M8 24 Nm 212 in lb M10 35 Nm 310 in lb 1 5 Tire inflation pressure Maintain tire pressure at the air pressures specified in figure 1 1 When checking the tire pressure examine the tires for wear cuts bruises and...

Page 8: ...has to be determined with all the installed equipment including engine oil cooling liquid being considered but without fuel Figure 1 6 shows how to conduct the C G determination All measurements including a listing of all the installed equipment has to be noted in the separate weight and balance calculation form an example is given in figure 1 7 This form has to be placed in the aircraft so every ...

Page 9: ...C G calculation recommendation which has to be carried out prior to each flight is provided in the Pilot Operating Handbook Section 4 Figure 1 6 note illustration below is for Aeropro aircraft prior to s n 18106 see individual aircraft documents for illustration appropriate for any specific aircraft ...

Page 10: ...March 21 2020 Figure 1 7 WEIGHT AND CG POSITION RECORD Serial Number Registration Aircraft leveling Values Weighed Main wheel Starboard side Mrh kg L mm Port side Mlh kg L1 mm Nose wheel Mpr kg Result weight Mres kg CG position mm mm MAC Date Performed by ...

Page 11: ...on Sources Airframe and Engine Components Aeropro CZ Hlavní 439 687 25 HLUK Czech Republic phone 420 572 582 194 fax 420 572 582 195 e mail aeroprocz seznam cz Aerotrek Aircraft Rollison Light Sport Aircraft Inc 34 E Antioch Road Bloomfield IN 47424 USA phone 812 384 4972 e mail info aerotrek aero web www aerotrek aero Engine Components Refer to ROTAX Engine Operator s Manual 912 Series Section 14...

Page 12: ...gure 1 9 part description or location part description engine compartment Rotax oil filter element gasket for oil filter gasket for oil drain screw air cleaner element all gaskets in general exhaust system retaining springs self locking nuts in general propeller screws engine mount screws engine shock mounts throttle control cables other specific engine components refer to Rotax Engine Maintenance...

Page 13: ...round Do not operate engine if bystanders are close In the interest of safety the aircraft must not be left unattended while the engine is running Keep an aircraft log and respect engine and aircraft maintenance schedules Keep the engine in top operating condition at all the times Do not operate any aircraft which is not properly maintained or has engine operating irregularities which have not bee...

Page 14: ...orage 2 3 2 11 Returning aircraft to service 2 3 2 12 Servicing 2 4 2 13 Fuel 2 4 2 14 Fuel drains 2 4 2 15 Engine oil 2 4 2 16 Engine induction air filter 2 4 2 17 Battery 2 4 2 18 Tires 2 5 2 19 Hydraulic brake system 2 7 2 20 Cleaning 2 8 2 21 Windshield and windows 2 8 2 22 Plastic trim 2 8 2 23 Painted surfaces 2 8 2 24 Aluminum surfaces 2 8 2 25 Engine and engine compartment 2 8 2 26 Upholst...

Page 15: ...e prepare a fixing stand to be located underneath the aircraft thus assuring stable support and positioning for the whole aircraft To jack up the aircraft you can also use special jacking stands designed for large aircraft if the size and frame configurations are appropriate 2 4 Jacking Refer to paragraph 2 3 The aircraft does not feature further jacking points except for changing main wheels Doin...

Page 16: ...llow the aircraft to be stored for long periods of time without damage to the airframe Nevertheless we recommend to store the aircraft in a dry hanger to keep paintwork and metal parts in good condition For storage periods not exceeding 90 days the following methods of treatment are suggested a Fill fuel tank with correct grade of gasoline b Clean and wax aircraft thoroughly c Clean any oil or gre...

Page 17: ...s for required intervals for oil and filter changes Change oil at least every 12 months even if less than the specified hours have accumulated Reduce this period for prolonged operation in dusty areas in cold climates where sludging conditions exist or where short flights and long idle periods are encountered which cause sludging conditions 2 16 Engine induction air filter The induction air filter...

Page 18: ...and spillage Remove oil grease and mud from tires with soap and water Figure 2 1 Rotax 912ULS engine installation 1 Controls lever for carburetor heat 2 Clip for elastic air tube 3 Holder for oil cooler one screw M5 4 Oil cooler Note Recommended tire pressures should be maintained Especially in cold weather remember that any drop in temperature of the air inside a tire causes a corresponding drop ...

Page 19: ...Maintenance Manual AEROPRO CZ 2 6 Maintenance Manual March 21 2020 Figure 2 2 ...

Page 20: ...ils First 25 hours 6 Engine oil system Drain and refill Oil with recommended engine oil grade replace oil filter 100 hours 4 Induction air filter Clean filter per paragraph 2 16 replace as required 7 Battery Check for correct voltage level Charge or replace if required Refer to paragraph 2 17 for details 8 Tires Maintain correct tire inflation as listed in figure 1 1 Also refer to paragraph 2 18 f...

Page 21: ...eriod the aircraft may be waxed with a good automotive wax A heavier coating of wax on the leading edge of the wing and tail and on the engine cowling will help reduce the abrasion encountered in these areas 2 24 Aluminum surfaces Some aluminum surfaces will require a minimum of care due to their anodized coating but should never be neglected Many good aluminum cleaners are available from commerci...

Page 22: ...racked wheel hubs and install new parts 2 29 Lubrication The A240 has been designed to have as few lubrication points as possible For areas that do require lubrication regular grease should be used The following list details the areas that will require occasional lubrication a wing main bolts b wing folding mechanism hinge c wing flap push pull rods connection and hinges d stabilizer mounting bolt...

Page 23: ...ontinued airworthiness c At each 200 hours the 100 hour items would be accomplished in addition to the items marked as 200 hour service as necessary to insure continued airworthiness d The numbers appearing in the special inspection item S i i column refer to data listed at the end of the inspection charts These items should be checked at each inspection interval to insure that applicable servicin...

Page 24: ... following making note of any discrepancies or abnormalities It is strongly recommended that the static test report form included in the AEROPRO Checklist B Service maintenance form is used during any run up inspection 1 engine temperatures and pressures 2 static rpm 3 magneto drop 4 engine response to changes in power 5 any unusual engine noises 6 fuel shut off valve function 7 idling speed 8 cha...

Page 25: ...n of the fuselage and is accessible through large vertically opening doors hinged on to the top of the door frames The aircraft is a side by side two seat configuration the seats being constructed of a fiberglass frame with fabric upholstery Pilots are fastened with four point safety belts anchored to the fuselage framework The engine is located in front of the cockpit separated from the cockpit b...

Page 26: ... aviation technician or a distributor of the acrylic material b Wrap a piece of extremely fine sandpaper or abrasive cloth around a rubber pad or block of wood Rub surface around scratch with a circular motion keeping abrasive constantly wet with clean water to prevent scratching surface further Use minimum pressure and cover an area large enough to prevent formation optical distortions c Continue...

Page 27: ...of Maintenance Heavy 3 10 4 Certification required A P Mechanic a Cut out the old windshield window using a jig saw without causing damage to the instrument board panel windshield plate and fuselage remove old rivets on the upper and side plates Remove the instrument board panel b Remove the remaining border of the windshield by the use of an appropriate prybar and sand off old glue to get a smoot...

Page 28: ...board panel 3 12 Cabin Doors The cockpit is accessed via a clear polycarbonate door on either side of the aircraft The doors are fitted to the airplane by hinges along its upper edge The doors are supported when in the open position by a gas pressure spring Both doors are lockable and have a glazed finish 3 13 Removal and Installation 3 13 1 Required Tools 8 10mm wench 3 13 2 Parts required None 3...

Page 29: ...Gas Struts on the door frame 5 Down holder of Gas Strut on the Fuselage 6 Rear door handle of the door 3 15 Lock 3 16 Removal and Installation 3 16 1 Required Tools 2 5 mm allen wrench needle nosed pliers screwdriver 3 16 2 Parts required Door handle set Loctite 243 medium strength 3 16 3 Level of Maintenance Light 3 16 4 Certification required Owner ...

Page 30: ...use the following steps For installation reverse the sequence a Remove screw 3 and take away rear pawl 6 b Remove screw 8 and take away inert pawl and from the oposite side take away the main door lock c For instalation use optimal lubricating Vaseline and use LOCTITE 243 medium strength to secure the screw 3 17 Seats 3 18 Description The pilot and co pilot seats are manufactured as a one piece fi...

Page 31: ...will vary with the particular job Scissors for trimming upholstery to size and a dull bladed putty knife are the only tools required for most trim work Use industrial rubber cement to hold mats and fabric edges in place 3 22 Baggage Compartment The baggage compartment of 700 x 530 x 570 mm size is located behind the cockpit seats It is accessible from between the seats and can hold baggage up to 6...

Page 32: ...Maintenance Manual AEROPRO CZ 3 8 Maintenance Manual March 21 2020 Figure 3 3 ...

Page 33: ... 3 3 illustrates the installation of the rescue system in the aircraft 3 27 Safety belts The seats are of a side by side arrangement situated in the fuselage centre section They consist of an upholstered fiberglass skeleton Each pilot s seat is equipped with four point safety belts anchored in the fuselage lattice work 3 28 Mapbox storage space for charts etc A small storage area is located on the...

Page 34: ... steel diagonal tubular stiffeners There is a 40 liter fuel tank built in the wing root section which is welded of aluminium alloy metal sheets Correct shape of the wing leading edge is guaranteed due to a fiberglass die formed shell glued on the leading edge tube The trailing edge is formed of a duralumin shaped piece The wing is fabric covered Below the wing trailing edge are the flaperons incor...

Page 35: ...Maintenance Manual AEROPRO CZ 4 2 Maintenance Manual March 21 2020 Figure 4 1 ...

Page 36: ...moval 4 4 1 Required Tools 10 12 13 14 mm wrench screwdriver and phillips head screwdriver needle nosed pliers 4 4 2 Parts required None 4 4 3 Level of Maintenance Heavy 4 4 4 Certification required A P Mechanic or LSA Repairman Maintenance Wing removal is most easily accomplished if three people are available to handle the wing Otherwise the wing should be supported with a sling when the fastenin...

Page 37: ...emoval 4 6 2 Parts required By the use of material 4 6 3 Level of Maintenance Heavy 4 6 4 Certification required A P Mechanic or LSA Repairman Maintenance The wing installation in general has to be carried out in reverse order to removal but we strongly recommend to read the following instructions prior to starting the installation 4 7 Installing strut to wing Connect main strut first to the wing ...

Page 38: ...ackward lengthwise along the fuselage thus reducing demands on storage space and road transport 4 11 Removal and installation Refer to paragraph 4 4 and 4 6 4 12 Tail unit 4 13 Description The tail unit is of the conventional arrangement with its load bearing frame welded using steel tubes A fabric covered rudder is fixed to the tail by three hinges The rudder control cables are connected to the b...

Page 39: ...anual March 21 2020 4 14 Removal and installation 4 14 1 Required Tools Similar to removal 4 14 2 Parts required By the use material 4 14 3 Level of Maintenance Heavy 4 14 4 Certification required A P Mechanic or LSA Repairman Maintenance Figure 4 4 ...

Page 40: ...lever for elevator control 3 elevator 4 rear strut 5 front strut 6 male threaded shank for rear strut 7 male threaded shank for front strut 8 screw for fuselage and strut 9 screw for stabilizer and strut 10 washer 11 self locking nut a remove the plate covering on the fuselage under the stabilizer disconnect route of the elevator trim see figure 4 4 N 10 b disconnect the five hinges between stabil...

Page 41: ...nce Manual AEROPRO CZ 4 8 Maintenance Manual March 21 2020 Figure 4 2 1 pitot line at fuselage 2 fuel line 3 rear strut wing connection 4 front strut wing connection 5 support strut 6 strut fuselage connection ...

Page 42: ...8 5 22 General Description 5 8 5 23 Trouble Shooting 5 9 5 24 Brake Master Cylinder 5 9 5 25 Removal and Installation 5 10 5 26 Repair 5 10 5 27 Hydraulic Brake Hoses 5 10 5 28 Wheel Brake Assemblies 5 11 5 29 Removal 5 11 5 30 Inspection and Repair 5 11 5 31 Reassembly 5 11 5 32 Installation 5 11 5 33 Checking Brake Lining Wear 5 11 5 34 Brake Lining Installation 5 12 5 35 Brake System Bleeding 5...

Page 43: ...rrect in accordance with paragraph 5 22 5 4 Main Gear Figure 5 1 illustrates the main landing gear The illustrations should be used in conjunction with the following procedures during removal and installation of component parts Disassembly inspection and repair and reassembly of the main undercarrage configurations are described in separate paragraphs for each configuration The webbed wheels havin...

Page 44: ...2 x 25 mm 5 5 3 Level of Maintenance Heavy 5 5 4 Certification required A P Mechanic or LSA Repairman Maintenance The following procedural steps remove the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual components You continue according to Figure 5 1 1 lift aeroplane and remove seat 2 remove the wheel pants 3 remove cable ties securing the brake li...

Page 45: ...in or similar R G L20 reinforcing with suitable carbon fiber fabrics Follow the instructions on the container for a successful completion of the repair If cracks in the undercarrage legs are present the main gear has to be replaced except if cracks are only related to the paint finish If in doubt always replace the main gear 5 7 Main Wheel Removal 5 7 1 Required Tools 27mm socket for axle nut 13mm...

Page 46: ...ic or LSA Repairman Maintenance a Clean all metal parts in solvent and dry thoroughly b Inspect wheel halves for cracks Cracked wheel halves shall be discarded and new parts used Sand out nicks gouges and corroded areas When the protective coating has been removed the area should be cleaned thoroughly primed with zinc chromate and painted with aluminum lacquer c If excessively warped or scored or ...

Page 47: ... be loosened f to locate an absorber of the front leg through the binding cable so that it does not throw out and the bottom absorber pin on the front leg to be disconnected g Disconnect the absorber stop from undercarriage leg h Unscrew the 4 x screws that hold the bearings on the front undercarriage leg 5 13 Repair If damage to any of the nose gear parts is detected then replace the affected par...

Page 48: ...or cracks Cracked wheel halves shall be discarded and new parts used Sand out nicks gouges and corroded areas When the protective coating has been removed the area should be cleaned thoroughly primed with zinc chromate and painted with aluminum lacquer c Carefully inspect bearings for damage and discoloration or noises when rotating Do not try to re lubricate the sealed bearings If in doubt about ...

Page 49: ...e spacer into the wheel hub before installing the second bearing to the hub 5 18 Wheel balancing Since uneven tire wear is usually the cause of wheel unbalance replacing the tire probably will correct this condition Tire and tube manufacturing tolerances permit a specified amount of static unbalance If a wheel shows evidence of unbalance during service it may be statically balanced 5 19 Nose wheel...

Page 50: ... warped brake disc Install new disc and brake linings Damaged or accumulated dirt restricting free movement of wheel brake parts Clean and repair or install new parts as necessary Brakes Fail to Operate Leak in system Install new parts Air in system Bleed system Lack of fluid in master cylinder Fill and bleed system Master cylinder defective Install a new cylinder 5 24 Brake master cylinder refer ...

Page 51: ... the main brake cylinder see 9 c Drain the brake fluid and disconnect the distributing tubes see 5 d Unscrew the screws for gripping the casing of the brake cylinder 5 26 Repair The master cylinder is limited to cleaning always install a new master cylinder if any defects are detected Use DOT 4 brake fluid 5 27 Hydraulic brake hoses All hydraulic hoses used for the brake system are flexible plasti...

Page 52: ...r See paragraph 5 37 c Inspect brake cylinder bore for scoring or corrosion A scored or pitted cylinder will leak or cause rapid brake fluid seal Install new brake cylinder replace caliper if scoring or corrosion is found d If the anchor bolts on the brake assembly are nicked or gouged they should be sanded smooth or replaced to prevent binding with the pressure plate or torque plate e Inspect whe...

Page 53: ...ppropriate fitting into the filler hole at top of the master cylinder b Immerse the free end of the flexible hose in a container with enough hydraulic fluid to cover the end of the hose c Connect a clean hydraulic pressure source such as a hydraulic hand pump or Hydro Fill unit to the bleeder valve in the wheel cylinder d As fluid is pumped into the system observe the immersed end of the hose at t...

Page 54: ...tem is comprised of push pull rods and bellcranks that which link the control stick to the ailerons 6 3 Trouble shooting For some of the remedy procedures in the following trouble shooting chart it may be necessary to re rig system and if so then refer to paragraph 6 17 Trouble Probable Cause Remedy Lost motion in the control stick Broken brackets or worn rod end bearings Replace worn or broken pa...

Page 55: ...front of the seats A translator connects the control sticks linkage to the aileron linkage which uses several bellcranks to establish the connection to the control surfaces An illustration of the aileron system is given in figure 6 1 Figure 6 1 1 2 3 4 2 5 6 3 9 10 7 8 1 Ailerons and flaps 2 Rod between flaps and mixer 3 Controls lever 4 Mixer controls lever 5 Rod on the bottom 6 Rod for control o...

Page 56: ...rol stick grips and disconnect wiring from the control stick switches c Remove wiring from the control stick tubes and linkage remember position of the control stick wiring and cable ties for reinstallation purposes Reassembly is done in reverse order to the steps outlined above Tighten screws and bolts to the torque settings in accordance to the values given in Section 1 6 7 Aileron and Flap Cont...

Page 57: ...Maintenance Manual AEROPRO CZ 6 4 Maintenance Manual March 21 2020 Figure 6 2 ...

Page 58: ...ated in the fuselage refer to figure 6 1 for a detailed illustration Bellcranks need no regular servicing 6 12 Removal and installation Refer to paragraph 6 9 6 13 Ailerons and flaps 6 14 Description The ailerons are constructed from a fiberglass composite material hinged to the trailing edge of the wings 6 15 Removal and installation 6 15 1 Required Tools 2 pieces 8 mm wrench 6 15 2 Parts require...

Page 59: ...3 Level of Maintenance Heavy 6 17 4 Certification required A P Mechanic or LSA Repairman Maintenance a For the flaperon control levers to apply the correct range of input but will stabilize in the neutral position pattern see figure 6 2 ensure the control stick and wing flap lever are both set to the neutral position before completing the rig b Gradually set the length of the rods from the control...

Page 60: ...Maintenance Manual AEROPRO CZ 6 7 Maintenance Manual March 21 2020 ...

Page 61: ...No response to control stick fore and aft movement Quick release connector at aft end of push pull tube disconnected Join quick release connector properly Forward end of push pull tube disconnected Attach push pull tube correctly Connection between bellcrank and push pull tube disconnected Attach push pull tube correctly Binding or jumpy motion felt in movement of elevator Defective bellcrank pivo...

Page 62: ...tor skin If damage occurs under operation the skin can be repaired by replacing a whole section of the damaged fabric or for minor damage by a local repair using a patch Such repairs may only be carried out using the same materials as used for the aircraft fabrication Repairs of the lattice work The operator is only allowed to carry out repairs on the lattice work that does not require either use ...

Page 63: ...Maintenance Manual AEROPRO CZ 7 3 Maintenance Manual March 21 2020 Figure 7 1 1 controls stick ...

Page 64: ...ee play of push pull tubes and bellcrank 7 9 Rigging 8 9 1 Required Tools 14 mm open end wrench 8 9 2 Parts required Loctite 243 medium strength 8 9 3 Level of Maintenance Heavy 8 9 4 Certification required A P Mechanic or LSA Repairman Maintenance a Locate neutral position of elevators by streamlining elevators with stabilizer b Place an inclinometer on the elevator and set to zero c Check for ce...

Page 65: ...evator trim control system 8 2 Description The aircraft trim control lever is located on the floor on a longitudinal tube and its motion is directed by means of cables and bowden cables to the elevator trim tab 8 3 Trouble Shooting TROUBLE PROBABLE CAUSE REMEDY Trim tab fails to move Broken controls cable Replace cable Unconnected cable on the trim tab lever Check all controls road Incorrect trim ...

Page 66: ...intenance Manual AEROPRO CZ 8 2 Maintenance Manual March 21 2020 Figure 8 1 24 Leathern circlet 44 Controls lever 45 Circlet for holder of cable 46 Controls cable 56 Bowden cable 61 Screw 91 Washer 86 Nut ...

Page 67: ...tural and if so will require no further servicing 8 6 Trim lever 8 7 Removal and installation 8 7 1 Required Tools screwdriver 7 mm open end wrench 8 7 2 Parts required Loctite 243 medium strength 8 7 3 Level of Maintenance Light 8 7 4 Certification required A P Mechanic or LSA Repairman Maintenance a Remove the seats b Unscrew the rod screws of the bowden cable in the cockpit under the seat c Uns...

Page 68: ...6 x 20 mm 8 13 3 Level of Maintenance Light 8 13 4 Certification required LSA Repairman Maintenance or Owner a Move controls lever to the center position b Trim tab must be in the center position c Check for correct movement of trim tab Pushing the control lever to the forward and checking the Trim Tab moves downward Note Always use a new cotter pin when reestablishing the connection of push pull ...

Page 69: ... the floor The pedal motion is transferred by steel cables to the rudder 9 3 Trouble Shooting Trouble Probable Cause Remedy Rudder does not respond to pedal movement Broken or disconnected cables Connect or replace cables Binding or jumpy movement of rudder pedals For trigear aircraft possible problem with nosewheel steering cable adjustment Properly adjust nosewheel steering cables Cables not rid...

Page 70: ...reinstallation e Rig system in accordance with applicable paragraph in this section safety clevises and reinstall all items removed in step a and b 9 6 Rudder 9 7 Removal and installation 9 7 1 Required Tools 10mm wrench 9 7 2 Parts required Self locking nut M6 safetying 9 7 3 Level of Maintenance Heavy 9 7 4 Certification required A P Mechanic or LSA Repairman Maintenance c Disconnect cables from...

Page 71: ...tion e When installating the new cable feed the cable though the cockpit end of the cable at the same point from where it was removed f When installing the cables you will have to use Nicopress tools to seal the ends of cables you can prepare the front end out side of fuselage before starting the installation g Set the rudder pedals in the neutral position and ensure the rudder surface is also set...

Page 72: ... 10 16 Replacement 10 12 10 17 Static run up procedures 10 12 10 18 Engine mount 10 12 10 19 Removal and installation 10 12 10 20 Repair 10 13 10 21 Shock mount pads 10 13 10 22 Engine oil system 10 13 10 23 Trouble shooting 10 13 10 24 Filter element removal and installation 10 14 10 25 Engine fuel system 10 15 10 26 Carburetor removal and installation 10 15 10 27 Idle speed adjustment 10 16 10 2...

Page 73: ...ber composites 10 2 Removal and installation 11 2 1 Required Tools Screwdriver 11 2 2 Parts required None 11 2 3 Level of Maintenance Light 11 2 4 Certification required Owner Removal and installation of engine cowling is accomplished by initially releasing the quick release fasteners at the side surfaces Then remove the upper cowling by disengaging it from top of the fire wall then lifting the up...

Page 74: ...inside surface of the cowling is coated heavily with oil and dirt allow solvent to soak until the foreign material can be removed Wash painted surfaces of the cowling with a solution of mild soap and water and rinse thoroughly After washing it is recommended to apply a coat of wax to the painted surface to prolong paint life After cleaning inspect the cowling for cracks Repair all defects to preve...

Page 75: ...ith integrated shock absorber and overload clutch Specific engine datas are given in figure 11 2 10 6 Engine data Figure 10 2 Descriptions 912 ULS Dimensions Bore 3 31 in Stroke 2 40 in Displacement 82 5 in3 1352 cc Compression ratio 11 1 Weight without exhaust radiator air intake system 134 lb Speed Takeoff engine rpm maximum 5800 rpm Continuous engine rpm maximum 5500 rpm Idle speed range prefer...

Page 76: ...ark plugs fouled or improperly gapped Remove and clean Check gaps and insulators Check cables to persistently fouled plugs Replace defective plugs Defective magnetos or ignition amplifiers Replace defective parts in accordance with Rotax maintenance manual Spark plugs loose Tighten to specified torque Water in fuel system Drain fuel tank sump fuel lines and carburetors Excessive starter slippage R...

Page 77: ...maged ignition lead Float chamber bleed hoses disconnected or broken Connect or replace bleed hoses Sluggish operation and low power Throttle not opening completely Rig per paragraph 10 37 Spark plugs fouled or improperly gapped Remove clean and regap or install new plugs Incorrect carburetor synchronizing Synchronize carburetors in accordance to Rotax maintenance manual Incorrect carburetor mixtu...

Page 78: ...ter gripper 4 10 mm allen wrench 8 17 mm wrench 10 8 2 Parts required Insulating tape 10 8 3 Level of Maintenance Heavy 10 8 4 Certification required A P Mechanic or LSA Repairman Maintenance If the engine is to be placed in storage or returned to the manufacturer for overhaul proper preparatory steps should be taken prior to beginning the removal procedure Refer to Temporary storage in section 2 ...

Page 79: ...tion and the numbers of washers used Steady the engine by hand as the last of the bolts are removed q Disengage exhaust retaining springs and remove the exhaust system r Remove exhaust downpipes from cylinder head mark each downpipe location for reinstallation s Unscrew engine to mount attachment screws and remove engine mount t Carefully guide the disconnected components away from the engine asse...

Page 80: ...ive years whichever occurs first f For major engine repairs refer to the manufacturer s overhaul and repair manual 10 12 Engine build up Engine build up consists of installation of parts accessories and components to the basic engine to build up an engine unit ready for installation on the aircraft All safety wire lock washers plain nuts elastic stop nuts gaskets and all rubber connections should ...

Page 81: ...items that were removed from the engine after it was removed from the aircraft Figure 10 3 1 Gearbox 2 Engine Rotax 912ULS 3 Carburetors 4 Starter 5 Oil filter 6 Engine mount M12 7 Engine shock absorber 8 Holder for shock absorber 9 Socket head screws M8x80 10 9 10 Rubber chock mount pads 11 Collar bush 12 Shaped washer 13 Shelf locking nut M8 a Hoist engine assembly at the inlet manifold on top o...

Page 82: ...Connector Box on firewall k Install all clamps attaching the wires and cables to the engine engine mount or attached brackets l Install the propeller and spinner refer to Section 12 m Make sure the routing of exhaust pipes does not interfere with surrounding components and tighten the retaining screws on cylinder heads to a maximum torque value of 26 Nm 230 in lb n Service engine with proper grade...

Page 83: ...hoke control for proper rigging 3 Check spark plugs and ignition system for settings and conditions 4 Check both magnetos are working properly 5 Check condition of induction air filter Clean if necessary 6 Perform an engine compression check Refer to engine Manufacturer s Manual 10 18 Engine mount refer to figure 10 2 The engine mount is composed of sections of tubing welded together and reinforce...

Page 84: ...ngine Operators Manual for detailed information 10 23 Trouble shooting The following listing should be understood as quick reference guide to locate particular trouble which may occur to the engine oil system For detailed information refer to the engine manufacturers Maintenance manual Trouble Probable Cause Remedy No oil pressure No oil in system Fill system with proper grade and quantity of oil ...

Page 85: ...d Hold ground running above 2500 rpm to a minimum 10 24 Oil change with filter element removal and installation 10 24 1 Required Tools screwdriver edge cutter 10 24 2 Parts required New filter element cable ties 10 24 3 Level of Maintenance Light 10 24 4 Certification required Rotax certified technician a Remove the engine cowling as necessary for access b Unscrew the oil filter from the oil pump ...

Page 86: ...the preceding steps for reinstallation i Rig the controls in accordance with applicable paragraph in this section j Check the carburetor throttle arm to the idle stop arm attachment for security and proper safety at each normal engine inspection 10 27 Idle speed adjustment 10 27 1 Required Tools Screwdriver 10 27 2 Parts required Lock screw Note Before discarding the removed filter element cut the...

Page 87: ...abin which permits air from an exhaust heated source to be selected in the event carburetor icing or if filter icing should be encountered 10 30 Removal and installation Remove and install airbox system as outlined in paragraph 10 26 10 31 Ignition system The Rotax 912 series engines are equipped with a dual ignition unit of a breakerless capacitor discharge design with an integrated generator The...

Page 88: ...revent spark plug noise in the radio and the spark plugs have an internal resistor to provide longer terminal life Spark plug life will vary with operating conditions A spark plug that is kept clean and properly gapped will give a better and longer service than one that is allowed to collect lead deposits and is improperly gapped The correct spark plug and gap setting is given in paragraph 10 1 10...

Page 89: ...ull range of travel that it locks securely if equipped with a locking device and that the arm or lever which the control operates moves through its full arc of travel 10 37 Throttle control 10 37 1 Required Tools 8 10 mm open end wrench 10 37 2 Parts required Lock screw 10 37 3 Level of Maintenance Light 10 37 4 Certification required A P Mechanic or LSA Repairman Maintenance Caution Whenever engi...

Page 90: ...n the carburetor achieve their maximum travel at the same time If required readjust controls at the locknut on carburetor arm e Tighten the rod end locknuts at the carburetor end of the control Be sure to maintain sufficient thread engagement between the rod end and the control 10 39 Carburetor heat control a Push the carburetor heat control to off position b Check the cable tension for proper set...

Page 91: ...emove clean and tighten all terminal connections Defective starter motor Repair or install a new starter motor 10 42 Removal and installation 10 42 1 Required Tools Screwdriver 10 mm wrench 10 42 2 Parts required Self locking nut M6 insulating tape 10 42 3 Level of Maintenance Light 10 42 4 Certification required Rotax certified technician a Remove the cowling as required for access b Disconnect t...

Page 92: ...the muffler then remove the muffler e Carefully remove the downpipes and unscrew exhaust probes from each of the downpipes Figure 10 5 1 2x rear exhaust pipe 2 2x front exhaust pipe 3 muffler bracket 4 muffler shroud for cockpit heating 5 muffler 10 45 Inspection Inspection of the exhaust system must be very thorough because the cabin heating system uses air heated by the heat exchangers of the ex...

Page 93: ...te 10 on Inspection Checklist Start the engine with the throttle closed and choke activated open throttle renders starting carb ineffective As performance of electric starter is greatly reduced when cold limit starting attempts to periods not longer than 10 seconds and with a well charged battery adding a second battery will not improve cold starts 10 48 Hot weather Engine mis starts characterized...

Page 94: ...Maintenance Manual AEROPRO CZ 10 23 Maintenance Manual March 21 2020 ...

Page 95: ...main Maintenance Manual 10a 7 several Rotax 914 manual page reprints 10a 10 10 1 Engine cowling The engine cowling is comprised of an upper and lower cowl segment Quick release screw fasteners are used at the cowling to fuselage attachment points fixing the cowling to the firewall Quick release screws are also used along the side surfaces to hold lower cowling and upper cowling segments together B...

Page 96: ...f wax to the painted surface to prolong paint life After cleaning inspect the cowling for cracks Repair all defects to prevent spread of any damage 10 4 Repair 11 4 1 Required Tools As required 11 4 2 Parts required Epoxy Resin carbon fiber tape fabrics 11 4 3 Level of Maintenance Heavy 11 4 4 Certification required A P Mechanic or LSA Repairman Maintenance If cowling skins are extensively damaged...

Page 97: ...ystem 134 lb Speed Takeoff engine rpm maximum 5800 rpm 5800 rpm max 5 minutes Continuous engine rpm maximum 5500 rpm 5500 rpm Idle speed range preferably appox 1550 rpm 1450 1650 rpm 1450 1650 rpm Gear ratio 2 43 1 Performance Takeoff performance at 5800 rpm max 5 min 100 hp 84 5 kW 115 hp Continuous performance at 5500 rpm 92 hp 73 5 kW 100 hp Acceleration Max negative g for 5 seconds 0 5 Manifol...

Page 98: ...retor Spark plugs fouled or improperly gapped Remove and clean Check gaps and insulators Check cables to persistently fouled plugs Replace defective plugs Defective magnetos or ignition amplifiers Replace defective parts in accordance with Rotax maintenance manual Spark plugs loose Tighten to specified torque Water in fuel system Drain fuel tank sump fuel lines and carburetors Excessive starter sl...

Page 99: ...loat chamber bleed hoses disconnected or broken Connect or replace bleed hoses Sluggish operation and low power Throttle not opening completely Rig per paragraph 10 37 Spark plugs fouled or improperly gapped Remove clean and regap or install new plugs Incorrect carburetor synchronizing Synchronize carburetors in accordance to Rotax maintenance manual Incorrect carburetor mixture setting Adjust car...

Page 100: ...ine engine Metal particles from damaged pump may have entered engine oil passages Oil pressure line broken disconnected or pinched Inspect replace or connect line Internal leak burned bearings or damaged gasket Major overhaul Oil leak at propeller shaft Damaged propeller driveshaft seal Replace in accordance with Rotax maintenance manual Low compression Cylinder wall coating worn Replace cylinder ...

Page 101: ...nt refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 17 Static run up procedure refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 18 Engine mount refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 19 Removal a...

Page 102: ...l plus all relevant information in the Rotax 914 engine manuals 10 34 Spark plugs refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 35 Engine controls refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals and information in the Aeropro CZ POH for aircraft with 914UL engine 10 36...

Page 103: ...e weather maintenance refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 47 Cold weather refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 48 Hot weather refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10 49 Du...

Page 104: ...RO CZ 10a 10 Maintenance Manual March 21 2020 reprinted from Rotax 914 Series Line Maintenance Manual Edition 2 Rev 0 dated January 01 2010 note check latest version Rotax 914 Series Maintenance Manual for current information ...

Page 105: ...Maintenance Manual AEROPRO CZ 10a 11 Maintenance Manual March 21 2020 ...

Page 106: ...Maintenance Manual AEROPRO CZ 10a 12 Maintenance Manual March 21 2020 ...

Page 107: ...Maintenance Manual AEROPRO CZ 10a 13 Maintenance Manual March 21 2020 ...

Page 108: ...vers the fuel to the carburetors The amount of fuel in the tank is indicated by a visual sight gauge which is a part of each tank Minimum fuel quantity in the header tank is visually indicated by the lighting of a warning light on the instrument panel The remaining fuel i e 1 gallon is normally sufficient enough for 15 minutes of flight at moderate power settings The fuel drain valve outlet is beh...

Page 109: ...ction or open circuit Tighten connections repair or replace wiring Defective fuel quantity indicator or transmitter Refer to Section 15 Fuel overflow from carburetor Binding float valve or dirt in floater chamber Clean and repair carburetor Plugged fuel distributor or fuel return line jet Clean fuel distributor thoroughly Pressurized fuel tank Plugged fuel vent See paragraph 11 14 11 5 Fuel tank 1...

Page 110: ...ank d Disconnect fuel hose connected to the fuel pump e Remove the two metal strips securing the header tank i To install header tank reverse the preceding steps Be sure grounding is secure in accordance with paragraph 11 3 Figure 11 1 Note Apply appropriate liquid sealant to the threads of drain valve and fuel line connector while reassembling the system ...

Page 111: ...be to slightly pressurize the tank If air can be blown into tank vent line is open c After tank is slightly pressurized insert end of rubber tube into a container of water and watch for a continuous stream of bubbles which indicates the vent line is clear from obstucles 11 12 Fuel shut off valve There is a two position ON OFF fuel shut off valve for each wing tank located above the pilots head on ...

Page 112: ...de fuel for both carburetors The fuel distributor is located on top of the engine Pressurized fuel from the fuel pump is routed to both carburetors while surplus of fuel flows back to the fuel tank through a return hose A 0 02 inch jet is provided to the return hose fitting to ensure the required fuel pressure A fuel pressure gauge may be connected to check fuel pressure at the opposite side of th...

Page 113: ...lamp securing distributor block to engine d Disconnect hose fittings from the distributor e Reverse preceding steps for reinstallation Observe precautions outlined in paragraph 11 3 11 18 Inspection Inspect fuel distributor for clean condition especially check jet drillings for the return hose and the fuel pressure gauge connection to be unplugged Clean hose fittings thoroughly before reassembly C...

Page 114: ...tion of the header tank 11 2 11 8 Fuel filter 11 2 11 9 Removal and installation 11 2 11 10 Fuel vent 11 2 11 11 Checking 11 2 11 12 Fuel shut off valve 11 3 11 13 Removal and installation 11 3 11 14 Fuel drain valve 11 3 11 15 Removal and installation 11 3 11 16 Fuel distributor system 11 4 11 17 Removal and installation 11 4 11 18 Inspection 11 5 11 1 Fuel system 11 2 Description The fuel is gra...

Page 115: ...shut off valve Replace shut off valve Fuel line plugged Clean out or replace fuel line Defective mechanical fuel pump Replace fuel pump Fuel starvation after starting Partial fuel flow from the preceding causes Use the preceding remedies Plugged fuel vent See paragraph 11 14 Water in fuel Drain fuel tank sumps fuel lines and carburetors No fuel quantity indication Fuel tanks empty Service with pro...

Page 116: ...eceding steps Be sure grounding is secure in accordance with paragraph 11 3 11 8 Fuel filter The fuel filter is located under the left seat and is attached to the fuel hose a few inches downstream of the fuel header tank Refer to Section 2 for replacement intervals of the fuel filter 11 9 Removal and installation 11 9 1 Required Tools screwdriver clamp tongs 11 9 2 Parts required Hose clamps fuel ...

Page 117: ...l c Disconnect fuel line at the firewall and at the rear end hose connection d Remove screws attaching shut off valve e Withdraw shut off valve assembly from the holder on the fuselage f Disconnect fuel lines from shut off valve g Reverse the preceding steps for installation 11 14 Fuel drain valve A fuel drain valve is installed to the bottom of the header tank Access is possible from beneath the ...

Page 118: ... left seat and there is not an engine mounted mechanic fuel pump NOTE When replacing the fuel filter on older planes we recommend installing the fuel filter under the left seat and using the recommended fuel filter as listed on the Inspection Checklist and replacing the fuel filter under the left side of the instrument panel with a new length of fuel line NOTE The latest version Inspection Checkli...

Page 119: ... for clean condition especially check jet drillings for the return hose and the fuel pressure gauge connection to be unplugged Clean hose fittings thoroughly before reassembly Check also the jet provided in the return hose fitting for clean and unblocked condition Caution Remember position of return hose fitting for reinstallation Caution Always use new copper washer sealing for reinstallation of ...

Page 120: ...acturers manual for further instruction 12 3 Removal refer to figure 12 1 12 3 1 Required Tools 3 6 mm Allen wrench screwdriver 12 3 2 Parts required Safety wire 9x stainless steel screws M4 12 3 3 Level of Maintenance Heavy 12 2 4 Certification required A P or LSRM A a Remove spinner b Remove bolts and pull propeller forward to remove Use care to avoid damage to bulkheads as propeller is removed ...

Page 121: ...s must be positioned so propeller blades will emerge from the spinner with ample clearance b Set prop blade pitch and tighten the mounting bolts to be torqued in accordance with the prop manufacturer s manual specifications c Safety wire propeller mounting bolts 3 as needed unless secured instead with nylock nuts d Install spinner When fitting the spinner use the fixing screws Do not overtighten t...

Page 122: ...ol in gradually decreases flow shutting off flow completely when the control is fully pushed in 13 5 Trouble shooting Most of the operational troubles in the heating and ventilating systems are caused by a sticking or binding air valve and its control damaged air ducting or defects in the exhaust muffler In most cases the valve or control can be freed by proper lubrication Damaged or broken parts ...

Page 123: ...their controls after repair or replacement Figure 13 1 1 2 1 Front intake 2 Muffler wrap for cockpit heating 3 Rear hose 4 Air valve for cockpit heat control 5 Control holder 6 Clamps 7 Plate connecting unit to firewall note the Rotax 914UL engine installation has some small but obvious differences 13 7 Ventilation system 13 8 Description Figure 13 2 The ventilating system is comprised of a NACA s...

Page 124: ...AEROPRO CZ 13 3 Maintenance Manual March 21 2020 Figure 13 2 1 NACA fresh air intake 2 tunnel for fresh air 3 valve 4 fresh air vents on off disk 13 9 Trouble shooting Damaged or broken parts must be repaired or replaced ...

Page 125: ...ating systems Emphasis is placed on trouble shooting and corrective measures only It does not deal with specific instrument repairs since this usually requires special equipment and data and should be handled by instrument specialists Federal Aviation Regulations require malfunctioning instruments be sent to an approved instrument overhaul and repair station or returned to manufacturer for servici...

Page 126: ...ew mounted on the aluminum frame backs 14 5 Removal and installation 14 5 1 Required Tools Wrench 10 mm wrench screwdriwer 14 5 2 Parts required Cable ties insulating tape 14 5 3 Level of Maintenance Light 14 5 4 Certification required A P or LSA Repairman Maintenance or Owner 14 6 Stationary panel The stationary panel is located at the lower center section of the cockpit frame It consistes of a m...

Page 127: ...nel 4 mounted panel 5 area for switches and auxiliary instrument 6 EIS engine instrument 7 engine brake cabin and carburetor heating control levers 8 area for flight instruments 9 area for COM and NAV instruments 10 start up engine and master switch note in the photos at left an older instrument panel is shown note in the photo below a newer 2019 instrument panel is shown ...

Page 128: ... c Pull out the upper edge of the frame and lift up to disengage the lower edge from the cockpit main frame d Disconnect wiring and hoses and remove panel e Reverse preceding steps for reinstallation Figure 14 2 1 right wing 2 pitot tube 3 hose dynamic pressure 4 airspeed indicator 5 vertical speed indicator 6 altimeter 7 n a 8 n a 9 instrument panel 14 8 Pitot and static system refer to figure 14...

Page 129: ...ce a partial obstruction To clear the hose disconnect it at the airspeed indicator Gently blow from the indicator end of line toward the pitot tube Replace any hose which has cracked hardened or show other signs of deterioration 14 14 Removing and installation of components refer to figure 14 1 14 2 14 14 1 Required Tools Edge cutter 14 14 2 Parts required Cable ties hoses as required 14 14 3 Leve...

Page 130: ... cable ties and line connections for security 14 17 Trouble shooting Altimeter Trouble Probable Cause Remedy Instrument fails to operate Static port plugged Check altimeter static port for obstruction Defective mechanism Substitute known good altimeter and check reading Replace indicator Incorrect indication Pointer not carefully set Reset hands with knob Leaking diaphragm Substitute known good al...

Page 131: ... NOTE For detailed information regarding the EIS basic informatoin is in Aeropro aircraft POH and with more specific information in the EIS Manual included with aircraft documentation 14 22 Removal and installation 14 26 1 Required Tools 3 mm allen wrench screwdriver edge cutter 14 26 2 Parts required Cable ties 4 x self locking nut M4 14 26 3 Level of Maintenance Light 14 26 4 Certification requi...

Page 132: ...ood EIS and check operation Replace EIS 14 24 Magnetic compass 14 25 Description The magnetic compass is liquid filled with expansion provisions to compensate for temperature changes It is equipped with compensating magnets adjustable from front of case No maintenance is required on compass except on occasional check on a compass rose for adjustment of compensation 14 26 Slip indicator A slip indi...

Page 133: ...ruments 15 3 15 13 Connecting avionic devices 15 3 15 14 Battery power system 15 3 15 15 Battery 15 3 15 16 Description 15 3 15 17 Removal and installation 15 3 15 18 Trouble shooting battery power system 15 4 15 19 Cleaning the battery 15 4 15 20 Testing the battery 15 4 15 21 Charging the battery 15 4 15 22 Alternator power system 15 5 15 23 Description 15 5 15 24 Removal and installation 15 5 1...

Page 134: ...rect current single wire negative ground electrical system A 12 volt battery supplies power for starting and furnishes a reserve source of power in the event of alternator failure An engine driven alternator is the normal source of power during flight and maintains a battery charge controlled by a voltage regulator 15 5 Master wiring system The aircraft is equipped with a master wiring system feat...

Page 135: ...15 Battery 15 16 Description The A240 uses a high tech Powersafe SBS8 battery which is 12v 7 amp hour capacity The battery is mounted below the right seat The battery installation is sealed and so requires no maintenance other than periodic charging during periods of disuse to maintain an adequate battery charge for good battery health and life 15 17 Removal and installation 16 19 1 Required Tools...

Page 136: ...nd connections in accordance with the preceding paragraph b Wipe the battery cable ends battery terminals and the entire surface of the battery with a clean cloth moistened with a solution of bicarbonate soda baking soda and water c Rinse with clear water wipe off excess water and allow battery to dry d Brighten up cable ends and battery terminals with emery cloth or a wire brush e Install the bat...

Page 137: ...m 15 28 Removal and installation 16 30 1 Required Tools 4 mm allen wrench 8 10 mm wrench screwdriver 16 30 2 Parts required 2 x self locking nut M5 insulating tape 16 30 3 Level of Maintenance Light 16 30 4 Certification required A P LSRM A or Owner a Remove the cowling instrument panel and seat b Disconnect battery leads and insulate as a safety precaution c Unplug the terminal connector on the r...

Page 138: ... 3 Check voltage at nav lights with master switch and nav light switch ON Should read battery voltage Replace switch One nav light out Lamp burned out Inspect lamp replace lamp Open circuit in wiring Test wiring for continuity Repair or replace wiring Anti collision strobe light out Flash tube burned out Test with new tube Replace tube Faulty wiring Test for continuity Repair or replace Circuit br...

Page 139: ... instrument and avionics lights 15 43 External receptacle not applicable 15 44 Description A standard type cigarette lighter socket is provided on the right side of the instrument panel This power socket is always connected to the aircraft electrical system and thus to the battery With proper adapter it is possible to trickle charge the aircraft battery through this panel power socket The trickle ...

Page 140: ... removed 15 51 Landing light 15 52 Description The small dual light landing taxi light is mounted on the front of the lower engine cowling This position facilitates the use as both a landing and a taxi light The landing taxi light is controlled by a switch located on the instrument panel The A220 A240 is not approved for night flight 15 53 Installation For installation of the landing light refer t...

Page 141: ...quipment running load Amps fuel indicator fuel pump Whelen LED strobe Whelen LED position lights EIS electronic engine instrument 1 0 0 5 approx 0 5 approx 0 4 Optional equipment running load transponder COM radio 1 3 0 5 2 5 Items not considered as part of running load External receptacle Landing light max 4 0 4 6 ...

Page 142: ...tion for welded frame repair Minor damages not affecting the aircraft airworthiness may be repaired provided the scope of work does not extend beyond cases described below The operator is allowed to carry out only such repairs of the lattice work in operation that do not require either use of a welding equipment or application of thermal treatment for straightening Straightening of such structural...

Page 143: ... system from DuPont Please contact the aircraft distributor for more information Note Do not paint the pitot tube gas caps or antenna covers which were not painted by the factory Caution Avoid thinner coming in contact with ABS parts or windows These areas should be cleaned with mild soap and water Do not use strong solvents such as xylol toluol or lacquer thinners ...

Page 144: ...nance Manual March 21 2020 Section 18 Wiring diagrams General wiring scheme This diagram is specific to the standard 912ULS installation refer to the Rotax 914UL manuals for additional or different wiring with that optional engine installation ...

Page 145: ...s of the affected aircraft These notices are titled by one of the following uppercase letters SAFETY ALERT Notifications that require immediate action SERVICE BULLETIN Notifications that do not require immediate action but do recommend future action NOTIFICATION Notifications that do not require necessarily recommended future action but are primarily for promulgation of continued airworthiness inf...

Page 146: ... the manufacturer can send the owner operator supplemental notification bulletins 3 The owner operator of an LSA airplane shall be responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery 4 The owner operator of an LSA airplane shall be responsible for complying with all manufacturer issued notices of corrective action and for comply...

Page 147: ...Manual AEROPRO CZ Maintenance Manual March 21 2020 MAINTENANCE MANUAL Supplement for A220 taildragger Aeropro CZ A220 ...

Page 148: ...ROPRO CZ 20 1 Maintenance Manual March 21 2020 1 9 2 CG calculation A specific C G calculation recommendation which has to be carried out prior to each flight is provided in the Pilot Operating Handbook Section 4 Figure 1 6 ...

Page 149: ...d C G position record sample only Serial Number Registr Mark Aircraft Levelling Values Weighed Main wheels right hand Mrh kg L mm left hand Mlh kg L1 Tail wheel Most kg Resulting weight Mres kg lbs C G position B Most x L L1 Mpr x L1 Mrst mm X B 50 mm _ X X x 100 1300 MAC Date Performed by ...

Page 150: ...Maintenance Manual AEROPRO CZ 20 3 Maintenance Manual March 21 2020 Figure 2 2 ...

Page 151: ... 5 21 Brake System 10 5 22 General Description 10 5 23 Trouble Shooting 10 5 24 Brake Master Cylinder 11 5 1 Landing Gear 5 2 General Description The A220 taildragger has a two wheel main undercarriage with a tail wheel The main landing gear is formed of composite construction wheels with low pressure tires of 800 6 size are provided with hydraulic disc brakes operated from control lever located o...

Page 152: ...d repair and reassembly of the main undercarriage configurations are described in separate paragraphs for each configuration The aluminum wheels have two flanges and a hub that is manufactured by an Aeropro supplier The flanges are attached to the wheel hub by 6mm thru bolts and nylock nuts as shown in figure 5 2 During assembly of the main wheel the thru bold nuts or cap screws as applicable shal...

Page 153: ...raft in accordance with figure 5 1 7 remove all bolts attaching main gear to fuselage 8 remove main gear assembly Installation of the main gear has to be carried out in reverse order to removal 5 6 Repair of fuselage and wheels fairings 5 6 1 Required Tools As required 5 6 2 Parts required New components as needed from Aeropro 5 6 3 Level of Maintenance Heavy 5 6 4 Certification required A P Mecha...

Page 154: ...ain Wheel Reassembly see instructions in A240 section of this Maintenance Manual Note If tire brake pads or brake disc have to be replaced it is not necessary to drain and disconnect the brake line Warning Injury can result from attempting to separate wheel halves with the tire inflated Avoid damaging wheel flanges when breaking tire beads loose A scratch gouge or nick may cause wheel failure Caut...

Page 155: ...4 Tail Wheel Removal and Installation 5 15 Disassembly 5 19 1 Required Tools 10 17 mm wrench 5 19 2 Parts required None 5 19 3 Level of Maintenance Light 5 19 4 Certification required LSA Repairman Maintenance or Owner a Remove tail wheel axle from wheel fairing then withdraw wheel from fork 5 16 Inspection and Repair 5 20 1 Required Tools Depending on condition 5 20 2 Parts required Depending on ...

Page 156: ...of the tail wheel 8 Axle for tail wheel 5 17 Reassembly 5 21 1 Required Tools 10 17 mm wrench 5 21 2 Parts required Loctite 243 medium strength 5 x self locking nut M6 cotter pin 2 x 40 mm 5 21 3 Level of Maintenance Light 5 21 4 Certification required A P Mechanic or LSA Repairman Maintenance a Insert thru bolts through wheel half b Position tire on second wheel half c Place one wheel half to pos...

Page 157: ...ng and rudder system are interconnected adjustment to one system may affect the other system Section 9 of the Aeropro A220 Maintenance Manual contains rigging instructions for the rudder system including info about the rudder centering system and rudder trim adjustment 5 21 Brake system 5 22 General description The hydraulic brake system consists of a master cylinders including a reservoir located...

Page 158: ...ders A220 s since 2009 have red Beringer brake cylinders note photo above is showing older brake system see separate information regarding the Beringer brake cylinders and the brake fluid reservoir in 2009 and newer A220 s note photo above does NOT show the rudder centering system and rudder trim adjustment system on all Aeropro aircraft starting in 2012 see Section 9 for information 1 brake pedal...

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