Breezer Maintenance Manual

BREEZER Maintenance Manual Page 1 of 48 Issue 1
BREEZER
LSA

Maintenance Manual

Issue 1


BREEZER Maintenance Manual

This Manual belongs to aircraft reg : ______________________

Type IKARUS BREEZER : _____________________

Serial No. : _____________________

Manufacturer: Aerosport Ltd. Ltd,
Aerosport Ltd. House,
Wolverhampton Airport,
Bobbington,
Stourbridge,
DY7 5DY.
UK.

Tel. +44 (0)1384 221550
Fax. +44 (0)1384 221560

This handbook should be kept with the aircraft.


1 CONTENTS

1 CONTENTS .................................................................................................................................... 3
2 ISSUE AMENDMENTS................................................................................................................... 4
3 GENERAL....................................................................................................................................... 5
3.4 Drawing and Dimensions .................................................................................................... 7
3.5 Equipment list ......................................................................................................................... 8
PlighL conLrols ..................................................................................................................................... 8
3.6 Sources for Spare parts...................................................................................................... 10
3.7 Consumable items.............................................................................................................. 10
3.8 Recommended Stocking List........................................................................................... 11
3.9 Engine Specifications......................................................................................................... 12
3.10 Air pressure for tyres and shock absorber: .............................................................. 12
3.11 Approved Oils/Coolants and Capacities................................................................ 12
3.12 Recommended fastener torque values .................................................................. 12
3.13 Defect and Fault Reporting ........................................................................................ 12
4 Weight and Balance............................................................................................................... 13
|nLroducLion ...................................................................................................................................... 13
Weighing ........................................................................................................................................... 13
5 INSPECTIONS.............................................................................................................................. 15
5.1 Daily Inspection / Pre-flight Inspection ................................................................................... 15
Walk-around inspection...................................................................................................................... 15
Starting the engine.............................................................................................................................. 17
5.2 25 hour inspection............................................................................................................... 18
5.3 50-Hour Inspection.............................................................................................................. 18
5.4 100-Hour or Annual Inspection........................................................................................ 19
5.5 LubricaLion plan...................................................................................................................... 19
6 LANDING GEAR ........................................................................................................................ 20
7 Brake system.............................................................................................................................. 21
8 ENGINE........................................................................................................................................ 23
9 FLIGHT CONTROLS.................................................................................................................... 24
9.2.1.1 Checking operation and deflection of the aileron control assembly.......................... 26
9.2.3.1 Checking operation and deflection of the elevator control assembly........................ 28
10 FUEL SYSTEM............................................................................................................................... 32
11 PROPELLERS ............................................................................................................................... 34
12 UTILITY PARTS.............................................................................................................................. 35
13 INSTRUMENTS AND AVIONICS ............................................................................................... 36
14 ELECTRICAL SYSTEM................................................................................................................. 37
15 STRUCTURAL REPAIRS............................................................................................................... 39
16 JACKING THE AIRCRAFT ......................................................................................................... 39
17 Cleaning....................................................................................................................................... 40
18 FEEDBACK FORM...................................................................................................................... 45
19 APPENDIX A MANDATORY MODIFICATIONS.................................................................. 46
20 APPENDIX B - APPROVED OPTIONAL MODIFICATIONS .................................................. 47


2 ISSUE AMENDMENTS

Issue
No.
Change/Description Date Signature
1

Initial Draft Issue
27/03/2006

3 GENERAL

3.1 Introduction
It is vital that this manual is read in conjunction with the Pilot Operators Handbook
(P.O.H.) that was issued with the aircraft. The P.O.H. contains all pertinent data that
relates to operating weights and limitations of that particular aircraft. This hand book
covers maintenance, servicing and other items that relate to aircraft sold in more than
one country and aircraft that have differing limitations.

If you do not have the P.O.H. of the aircraft that requires maintenance do not proceed
until this document is available. It can be obtained directly from the manufacturer
Aerosport Ltd, UK.

SERIOUS INJURY OR DEATH MAY RESULT FROM THE INCORRECT APPLICATION OF THIS
MANUAL.
The information given in the Maintenance Manual is based on data and experience which are
considered to be applicable for a skilled mechanic under normal working conditions.
It is a requirement that every organization or individual will possess the required special
tooling, training or experience to perform all tasks outlined.
We particularly emphasize that parts and accessories not supplied as genuine Aerosport
Ltd. parts are not verified for suitability by Aerosport Ltd. and thus are not authorized for
use.
Installation and/or use of such products may possibly change or negatively influence the
operational characteristics of the Breezer. For damages resulting from use of non-genuine
parts and accessories Aerosport Ltd. refuses any liability.
Non-authorized modifications as well as the use of components and auxiliary components not
corresponding to the installation instructions exclude any liability by the aircraft manufacturer.
Before carrying out maintenance work on the Breezer, carefully read the Maintenance Manual
if any passages of the Manual are not clearly understood or in case of any question, please
contact an authorized Service- or Distribution Center for Aerosport Ltd. Products.

3.2 Safety notice
This manual has been prepared as a guide to correctly service and maintain the Breezer.
This edition was primarily published to be used by aircraft mechanics who are already familiar
with all service procedures relating to the Breezer.
Please note that the instructions will apply only if proper hand tools and special service tools
are used.
Torque wrench tightening specifications must be strictly adhered to. Locking devices must be
installed or replaced with new ones, where specified. If the efficiency of a locking device is
impaired, it must be renewed.
It is your responsibility to be completely familiar with the safety instructions and technical
terms described in this manual. Non observance of the described procedures can cause a
serious malfunction which can result in loss of life.
It is, however, important to understand that this manual including safety notices and warnings
is not exhaustive. Aerosport Ltd. could not possibly know, evaluate and advise the user of all
conceivable ways in which service might be done or of the possible hazardous consequences
of each way.
Although the mere reading of such information does not eliminate the hazard, your
understanding of the information will promote its correct use. Always use common shop
safety practice.
3.3 Conversation table and abbreviations

Units of length:
1 m = 3,2808 ft 1 ft = 0,3048 m
1 cm = 0,3937 in 1 in = 2,5400 cm
1 mm = 0,0394 in 1 in = 25,400 mm
1 ft = 12 in

Units of area:
1 cm = 0,1550 sq in 1 sq in = 6,4516 cm
1 m = 10,7639 sq ft 1 sq ft = 0,0929 m

Units of volume:
1 cm = 0,0610 in 1 in = 16,3871 cm
1 m = 35,3157 ft 1 ft = 0,0283 m
1 dm = 1 L 1 L = 1 dm
1 L = 0,2642 gal (US) 1 gal (US) = 3,785 L
1 L = 0,2200 gal (UK) 1 gal (UK) = 4,546 L

Units of weight:
1 kg = 2,2046 lb 1 lb = 0,4536 kg

Units of density:
1 kg/dm = 0,036 lb/in 1 lb/in = 27,66 kg/dm
1 g/cm = 0,016 lb/ft 1 lb/ft = 62,43 g/cm

Units of force:
1 N = 0,2248 lbf 1 lbf = 4,4482 N

Units of pressure:
1 N/cm = 1,42 psi 1 psi = 0,69 N/cm

3.4 Drawing and Dimensions

Dimensions
[m] [ft]
A 8.71 28.6
B 6.66 21.8
C 2.13 7.0
D 2.78 9.1
E 2.04 6.7
F 1.54 5.1
G 1.36 4.5


3.5 Equipment list

This equipment list gives an approximate description of the BREEZER
aircraft

Design: Puselage
1he consLrucLion of Lhe load-bearing sLrucLure of Lhe fuselage is a convenLional
aluminium sLressed-skin design. L-shaped profiles are used as sLringers as re-
enforcemenL. 1he spars and ribs of Lhe verLical Lail form parL of Lhe fuselage
sLrucLure, Lhe skin of Lhe compleLely symmeLrical verLical Lail is formed by Lhe
glass-fibre panel which is a parL of Lhe fairing of Lhe upper side of Lhe fuselage.
1he upper side of Lhe fuselage fairing serves solely Lo shape Lhe sLrucLure. 1he
fuselage ends aL Lhe engine comparLmenL side aL a sLainless sLeel sheeL
(firewall). 1he engine is aLLached Lo Lhe firewall via engines mounLs made of
welded sLeel Lubing. A Lwo-piece, carbon-fibre cowling covers Lhe engine
comparLmenL.
CockpiL
1he cockpiL has Lwo side-by-side seaLs. 1o faciliLaLe boarding, parL of Lhe Lwo-
piece plexiglas canopy can be pushed back.
Wings
1he recLangular wing is of a convenLional design and comprises:
main spar
auxiliary spar
ribs
skin
1he fiLLings for Lhe flaps and Lhe ailerons are mounLed on Lhe auxiliary spar. Por
sLrengLh and weighL reasons, Lhe skin varies in Lhickness. Glass-fibre wing Lips
are aLLached Lo Lhe wing ends.
Lmpennage
As in Lhe case of Lhe wings, Lhe compleLely symmeLrical horizonLal Lail
comprises a main spar, an auxiliary spar, ribs, skin and glass-fibre surface Lips.
ConLrol surfaces, flaps
All conLrol surfaces and flaps are of Lhe same design and comprise a main spar,
ribs and skin.
PlighL conLrols
1he elevaLor and ailerons are operaLed by push rods whereas Lhe rudder is
operaLed convenLionally via conLrol cables. 1he nose wheel is also operaLed via
push rods which are aLLached Lo Lhe rudder pedals. LlevaLor forces can be
balanced by means of a Lrim Lab on Lhe elevaLor. 1he flaps are exLended
mechanically.
1rim
An elecLric piLch Lrim sysLem is conLrolled by swiLches on Lhe conLrol sLicks.
Pressing Lhe fronL swiLch lifLs Lhe Lrailing edge of Lhe Lrim Lab and resulLs in a
piLch down Lrim, pressing Lhe rear swiLch lowers Lhe Lrim Lab and resulLs in a
piLch up Lrim. A panel-mounLed meLer indicaLes Lrim posiLion.
Plaps
1he flap lever is locaLed in Lhe middle console beLween Lhe seaLs. |L is operaLed
in Lhe same way as a hand brake lever. 1he flaps can be exLended Lo Lhree
posiLions: 15, 25 and 45. 1he locking-in of Lhe flap lever can be heard as well
as felL. Should an inexperienced piloL noL be able Lo deLermine Lo whaL posiLion
he has exLended Lhe flaps, he can check Lhe posiLion by looking ouL of Lhe
cockpiL window and looking aL Lhe flaps.
An elecLrical flap exLension mechanism is an opLion. |L is operaLed by a rocker-
Lype swiLch and has a posiLion indicaLor.


Power Plant: 4 cylinder, 4-stroke liquid-cooled / air-cooled Rotax 912 UL
boxer motor 58 kW/80 hp or 100hp, with electrical starter, dual
electronic ignition, integrated reduction gear box, ground
adjustable 3-blade or 2-blade propeller.

Equipment: Highly effective hydraulic disc brakes with parking brake.
Flight instruments: Altimeter, airspeed indicator, compass,
bank indicator.
Engine instruments: RPM indicator, oil pressure indicator, oil
temperature gauge, water temperature gauge, fuel gauge.
Cabin heating, adjustable fresh-air inlets for both seats.
70 litre Fuel Tank.
High power/ low weight sealed lead acid battery, 12 Volt
power socket.
Seat Cushions, map pockets, floor mats.
Nose and main wheel fairings. Red or Blue stripe.
Radio Antenna.

Optional Items
Propellors Refer to POH for types cleared for use

Instruments
Vertical Speed Indicator - approx 80mm
Vertical Speed Indicator - approx 55mm
Operating Hours Meter
Artificial Horizon (Vacuum or electric)
Vertical Card Compass 57mm )
Fuel Computer (Fuel CAT)
Master Caution Warning System (Comco Design)

VHF Comms
Filser ATR500 radio (inc intercom)
Filser ATR600 radio (inc intercom)
Filser TRT 600 Mode S/C Transponder
Microair radio 760
Microair Transponder T2000 mode C

Exterior Lighting
Nose Wheel Landing Light (single bulb)
Strobe Light - mounted on the wing tips

3.6 Sources for Spare parts

Spare parts for the BREEZER can be obtained from the following sources :-

Your Dealer

Sports Planes Ltd
2059 E. Bear Ridge Cove
Draper, UT 84020
USA

Aircraft Spruce & Speciality

Aerosport Ltd. Ltd
Wolverhamton Airport
Stourbridge
UK
DY7 5DY

3.7 Consumable items

Tyres, oil, coolant, battery, spark plugs, oil filter, fuel filter, fuses,

Part Description

Tyres Trelleborg or Carlisle 4.00 x 6 4 ply rating or
5.30/4.50 x 6 6 ply rating
Inner tubes 4.00 x 6 angled valves
Coolant Glycol based @ 50% concentration
Engine oil Shell Advance VSX 4
Battery 12 Volt 12 AH YTX14-BS (Hawker)
Spark Plugs NGK DCPR7E (80hp) NGK DCPR8E (100hp)
Oil Filter Rotax 912 825 701
Fuel Filter Nylon mesh filter with 8mm connections
Fuses Automotive 12 volt blade fuses (30, 15 & 5 amp rating)

3.8 Recommended Stocking List

QTY Description Estimated Price

1 Set brake discs 75.00
2 Complete set brake pads 120.00
3 Tyres 90.00
3 Inner tubes 30.00
1 Suspension air pump 200.00
1 Metric socket set 50.00
1 Metric allen key set 15.00
1 Litre LHM fluid 10.00
1 Nose wheel axle 8.00
1 Front forks 175.00
1 Square tube 133.00
2 Fuel filters 10.00
8 Coolant radiator mounting rubbers 36.00
10 Long exhaust springs 20.00
5 Short exhaust springs 7.50
1 3 metres 8mm Trelleborg fuel hose 28.50
1 3 metres 6mm Trelleborg fuel hose 24.00
1 3 metres 8mm clear urethane hose 18.00
1 3 metres 6mm clear urethane hose 13.50
20 Size 11.5 fuel line clips 8.00
20 Size 12 fuel line clips 8.00
20 Size 14 fuel line clips 8.00
20 8mm rubber well nuts 12.00
20 4mm hex head screws 8.00
20 Complete engine cowl camlocs 52.00
10 Complete long wing nut camlocs 53.00
10 Complete short wing nut camlocs 53.00
10 Complete lower engine cowl fixings 4.00

1269.5

3.9 Engine Specifications

The BREEZER has optional power plants:

(i) The Rotax 912UL horizontally opposed, 4 cylinder 4 stroke engine, with water
cooled heads and oil and air cooled cylinders; it has a capacity of 1211 cc
and develops 80hp at 5800 rpm. The power is delivered to the fixed pitch
propeller via a gearbox having a ratio of 2.27:1.

(ii) The Rotax 912ULS, with same configuration to the 912UL, but with a larger
capacity of 1352 cc, higher compression ratio and developing 100 hp. Its
gearbox has a ratio of 2.43:1.

Full descriptions of the engine, its performance and maintenance
requirements are to be found in the Rotax manual. Please see the relevant
section for Engine limitations.
Exhaust system
The engine is fitted with a Heggemann Exhaust System. This system is built
largely from stainless steel components.
3.10 Air pressure for tyres and shock absorber:

Main wheels 1.8 - 2.5 bar 26 to 36 psi.

Front wheel 1.5 - 1.8 bar 22 to 26 psi.

3.11 Approved Oils/Coolants and Capacities

Refer to rotax manual

3.12 Recommended fastener torque values

Refer to Rotax manual

Neuform 8mm prop bolts torque - 19.9 ftlbs (27Nm)

3.13 Defect and Fault Reporting

All operating difficulties and equipment failures should be reported to your dealer or
the manufacturer using the Fault and Defect Reporting Form.

4 Weight and Balance

IntroductIon

PlighL performance and flighL characLerisLics described in Lhis handbook assume LhaL
Lhe weighL and CenLer of GraviLy limiLs of Lhe aircrafL are noL exceeded. 1he piloL is
responsible for ensuring LhaL Lhis 8reezer aeroplane is operaLed wiLhin Lhe weighL and
balance limiLaLions.
1his chapLer defines Lhe balance limiLaLions.

WarnIng
|L is prohibiLed Lo exceed Lhe maximum Lake-off weighL. 1his may lead Lo an
over-loading of Lhe 8reezer aircrafL and Lo a deLerioraLion in flighL performance
and characLerisLics.
|f Lhe CenLer of GraviLy limiLaLions are exceeded, Lhe conLrollabiliLy and sLabiliLy
of Lhe 8reezer aeroplane will be adversely affecLed.

WeIghIng

Weighing condiLions:
LquipmenL as per currenL equipmenL lisL
including all lubricanLs
including fuel reserve 0.5 US Gal (2 liLres)

Scales are placed under each wheel of Lhe aircrafL. 1he aeroplane musL be properly
aligned. 1he reference plane (8L) for CenLer of GraviLy measuremenLs is Lhe canopy
frame or Lhe canopy guiding rail, Lhe reference daLum (8P) is Lhe wing leading edge. (D)
is disLance from daLum Lo empLy CG posiLion.

1he disLances A and 8 can be deLermined by dropping a plumb bob from Lhe reference
daLum (wing leading edge). SubsequenLly, Lhe weighLs W1 and W2 (WL + WP) can be
measured.
1he locaLion of Lhe empLy weighL cg can be deLermined wiLh Lhe help of Lhe following
formula:

D = W2"A - W1"8
W1 + W2

Weighing diagram - 8reezer

8P - Peference DaLum (wing leading edge)
D - DisLance afL of daLum (empLy CG posiLion)
W1 - WeighL aL nose wheel
8 - DisLance forward from DaLum Lo nose wheel
W2 - WeighL aL main wheels
A - DisLance afL of DaLum Lo main wheels


1he mosL imporLanL arms, measured from Lhe DA1UM (wing leading edge), are:
PiloLs 25.6" (650 mm)
8aggage 52" (1320 mm)
Puel -9.45" (-240 mm)

1he operaLing CenLer of GraviLy range is:

Porward CenLer of GraviLy: 10.71" (272 mm) afL of DA1UM
(= 20% MAC)
Pearward CenLer of GraviLy 17.64" (448 mm) afL of DA1UM
(= 33% MAC)
CautIon

1he fuel momenL is always negaLive because Lhe fuel Lank lies in fronL of Lhe reference daLum.

Note
1he mosL forward CenLer of GraviLy posiLion is reached wiLh a full fuel Lank and a
piloL wiLh a weighL of 154 lbs / 70 kg
1he mosL rearward CenLer of GraviLy posiLion is reached wiLh 2.24 US Gal / 8.5
liLres of fuel and maximum piloL weighL.
1he piloL is responsible for ensuring LhaL Lhe M1OW is noL exceeded.
|f addiLional equipmenL is insLalled or if equipmenL is removed, Lhe empLy
weighL will increase or decrease accordingly.

Loading plan
Position weight x lever arm = moment
lb (kg) in (mm) lb in (kg mm)
Empty weight
1. Pilots 25.6" (650mm)
2. Baggage 52" (1320mm)
3. Fuel -9.45" (-240mm)
Total Weight lb (kg) Total Moment lb in (kg mm)
Total Moment lb in (kg mm)
centre of gravity CG = ------------------------------------------ = cm in (mm)
Total Weight lb (kg)
Allowable CG range 10.71" - 17.64" (272mm - 448mm) aft of DATUM

5 INSPECTIONS

5.1 Daily Inspection / Pre-flight Inspection

A pre-flight inspection should be undertaken before each flight. It is for your own safety and all
points should be carried out. In this way, small defects may be discovered and removed on
time.

Cabin control

a. Aircraft papers check
b. Check list available
c. Ignition key removed
d. Master switch off
e. Ignition both off
f. Amount of fuel sufficient for the planned flight
g. Throttle idle
h. Foreign body check complete
i. Baggage stored and secure

Walk-around inspection

Visually inspect the general condition of the aircraft, i.e. check the following stations for
damage (deformation, cracks), play and freedom of movement of the control surfaces, tight fit,
correct attachment and general condition. Also check ground and firewall for signs of leakage
(brake fluid, oil, coolant)!

Left main landing gear
(1) Landing gear strut visual inspection
(2) Landing gear attachment visual inspection
(3) Wheel fairing (if installed) visual inspection
(4) Tyre pressure check
(5) Tyre, wheel, brakes visual inspection
Left wing
(1) Wing skin visual inspection
(2) Wing tip, weight balance visual inspection
(3) Strobe light (if installed) visual inspection
(4) Aileron visual inspection
(5) Flaps visual inspection

Fuselage
(1) Skin visual inspection
(2) External items visual inspection

Empennage
(1) Stabilisers and control surfaces visual inspection
(2) Trim surfaces visual inspection

Right wing
(1) Wing skin visual inspection
(2) Flaps visual inspection
(3) Aileron visual inspection
(4) Wing tip, weight balance visual inspection
(5) Strobe light (if installed) visual inspection
(6) Pitot tube bore-hole free, clean

Right main landing gear
(1) Landing gear strut visual inspection
(2) Landing gear attachment visual inspection
(5) Tyre, wheel, brakes visual inspection

Front fuselage
(1) Upper cowling remove
(2) Oil level check*
(3) Coolant level check
(4) Fuel visual inspection
(5) Cowling visual inspection
(6) Air inlets no blockage
(7) Propeller visual inspection, secure**
(8) Propeller reduction gear turn propeller, check for unusual noises
(9) Hub visual inspection
(10) Nose landing gear visual inspection
(11) Tyre and wheel visual inspection

*When checking the oil level it is necessary to pump the oil back into the reservoir to
obtain a correct reading and to avoid overfilling. This can be done by removing the
oil filler cap and ensuring the master switch and magnetos are off and rotating the
propeller ONLY in the operating direction until a gurgling sound is heard from the
reservoir tank.

**
With composite propellers, minor damage to the external surface, such as a deep
scratch which breaches the outside fabric, can result in significant loss of strength and
a dangerous condition. For this reason it is important to inspect the blades carefully
before flight. Look particularly for scratches along the chord of the blade which may
have severed one or more yarns of fibre. When in doubt, seek expert advice.
Neuform propellers must be returned to Neuform in Germany for an inspection
every 500 hours or 2 years whichever comes first. Please refer to your propeller
operating manual.

Note

The following points should be checked once a day, before beginning flight operations, in
addition to the steps listed under 7.
Front fuselage
(14) Tank drain sample to check for water
(15) Engine mount visual inspection
(16) Exhaust system visual inspection
(17) Lubrication and fuel lines visual inspection
(18) Electric system and Bowden cables visual inspection
(19) Upper cowling secure

Starting the engine
Pre-flight inspection complete
Safety harness adjust and lock
Canopy lock
Flight controls free
Fuel valve open
Choke pull, if engine cold
Brakes apply
Throttle free, closed
Propeller area clear
Master switch ON
Ignition switch both ON
Alternator warning light illuminates
Oil pressure warning light illuminates
Starter turn, until engine starts
Oil pressure check

Periodic Maintenance and Inspection

5.2 25 hour inspection
LxLended pre-flighL inspecLion
Engine:
1. Check 25 hour inspection items in accordance with the ROTAX manual.
2. Check exhausL aLLachmenL screws and springs
Fuel system
1. Check tank internally for cleanliness.
2. Check fuel filter for cleanliness.
3. Check all fuel lines for degradation.

5.3 50-Hour Inspection

1. 25 hours inspecLion, plus:
2. 1horough cleaning of Lhe aeroplane, inside and ouL
3. Lngine: Check inspection items in accordance with the ROTAX manual.
4. Check secure aLLachmenL of propeller
5. Check engine hoses and lines for leakage and proper fiLLing
6. Check air filLer, blow ouL if necessary (from Lhe inside ouLl)
7. Check exhausL aLLachmenL screws and springs for cracks
8. Check nose-wheel landing gear and wheel for damage and cracks, grease bearings
9. Check main landing gear for secure aLLachmenL and damage
10. Check conLrol rods. Open Lhe hand-holes in Lhe fuselage (3) and in Lhe wings (2) and
check funcLionaliLy of bellcranks.
11. Check rudder conLrol cables for abrasion and secure aLLachmenL.
12. Grease Lhe hinges of Lhe: elevaLor, rudder and ailerons
13. Check Lhe aLLachmenL of Lhe horizonLal Lail and Lhe verLical Lail spar
14. Grease Lhe flap bearings
15. Check Lhe insLallaLion of Lhe ballisLic recovery sysLem, Lhe laying of Lhe aLLachmenL
sLraps, Lhe aLLachmenL of Lhe release grip.
16. Check baLLery
17. Check brakes for leakage, amounL of brake fluid and funcLion


5.4 100-Hour or Annual Inspection

1. 50 hours inspecLion, plus:
2. very careful check of:
3. Welded |oinLs of Lhe engine mounL, bolLs and rubber bearings of Lhe engine suspension
and Lhe engine mounL
4. Lngine: Perform 50 hours checks in accordance with ROTAX manual
5. Check nose wheel landing gear and rubber damper for damage and cracks, change Lyre
if necessary
6. Check main landing gear for damage, delaminaLion and secure aLLachmenL of Lhe bolLs,
change Lyres if necessary
7. Check Lhe brake discs and Lhe wheel bearings (play, lubricaLion)
8. Careful check of Lhe elecLrical sysLem and Lhe baLLery
9. Careful inspecLion of Lhe skin and Lhe riveLs for damage, secure aLLachmenL and cracks
10. Careful inspecLion of all insLrumenLs and avionics
11. Careful inspecLion of Lhe cockpiL inLerior:
for foreign bodies
Lhe flighL conLrols for play
wing aLLachmenL
12. Carry ouL lubricaLion in accordance wiLh Lhe lubricaLion plan.
13. If installed: Replace cockpit carbon monoxide detector in accordance with
manufacturers instructions.

5.5 LubrIcatIon pIan

Note
Only acid-free grease and oil should be used. |n order Lo prevenL unnecessary dirLying of Lhe
aircrafL, do noL use Loo much grease or oil.

Grease
1. Nose-wheel axle
2. Upper nose-wheel landing gear bearing
3. Plap mechanism and bearing
4. Canopy guide rails

Oil
1. LlevaLor, aileron and rudder hinges
2. 1rim Lab hinges
3. Movable parLs of Lhe flighL conLrols including Lhe bellcranks
4. Canopy lock
5. 8rake lever, rudder pedals
6. ConLrol cables

6 LANDING GEAR

The Breezer is equipped with a fixed tricycle undercarriage.

Main landing gear:
Each leg of the main landing gear is made of glass fibre. Each is fixed with five bolts at the
fuselage.

Nose landing gear:
The steerable nose landing gear is part of the engine mount.
Shock pads are used for shock absorbing

7 Brake system

The main landing gear wheels are provided with hydraulic disc-type brakes actuated by a
handlever which is installed between the seats.
Optionally both sticks are provided with a handlever.

For parking, a locking lever must be actuated which is positioned at the handlever.

General maintenance to ensure good brake performance

- Jack up each main wheel and spin the wheel checking the brake disc runs
centrally between the brake pads. If the brake disc runs biased over to one side
then when the brakes are applied, contact performance with the two pads will
be lost and the brakes become less efficient. To centralise the brake disc loosen
the brake caliper bolts and insert shims between the caliper and the mounting
bracket until the brake disc is centralised.

- If operating from a hard runway it is inevitable that the brakes will be worked
much harder than if operating from a grass runway. When taxying avoid
constantly holding pressure on the brake lever, this accelerates brake pad wear.
Apply the brakes periodically , say every 5 seconds instead.

- The engine idle speed must not be higher than 1750 rpm. To avoid a continual fast
taxy situation experiment lowering the idle speed to about 1600 rpm. This will
remove the need to constantly apply the brakes when taxying.

- The brake pads do not have a very thick lining even from new so do not be
fooled into thinking a set of part worn pads are ready for replacement.

- Keeping the brake lever pressure quite high ensures good brake performance.
The adjustment plunger on top of the brake fluid cylinder needs to be screwed
down periodically to maintain the pressure in the system.

- As the brakes slowly wear and the adjustment plunger is screwed down to its
lowest point it becomes necessary to top up the brake fluid level.

Replenishing the brake fluid

Remove the clevis pin and the brake lever.
Using some thin nose pliers remove the small aluminium cup and then very carefully
(try using 2 x pairs thin nose pliers) lift out the grey seal. This is quite brittle so take care.
Then obtain a small syringe or pipette and drop a small amount of LHM or Dexron
hydraulic fluid to raise the fluid level.
It is essential to use the correct fluid. Use LHM hydraulic fluid commonly used in
Citroen vehicles. This can be substituted for Dexron automatic transmission fluid.
Re-fit the grey seal and the aluminium cup.
Before re-fitting the brake lever use a small allen key to wind out the adjusting plunger
a few turns.
Re-fit the brake lever and clevis pin ensuring to re-adjust the allen key for the plunger.

Replacing the brake pads

Remove each wheel fairing and chock the wheels.
Ensure the parking brake is off and using an allen key unwind the adjusting plunger a
few turns.
Remove the 6mm caliper bolts. Be careful to note the position of any shims fitted.
Lift off the caliper being careful not to kink or distort the brake fluid line.
Remove the split pin and lift out each brake pad. Using a small piece of wood push or
gently lever back the caliper pistons.
Re-fit the new pads making sure to also fit the new split pin.
Re- fit the calliper over the disc and onto the mounting bracket. Secure the caliper
bolts making certain to re-fit any shims fitted.
Re-fit the wheel fairings.
Operate the brake lever to seat the new pads in the calipers and adjust the plunger
to acquire the necessary friction.

8 ENGINE

The BREEZER can be fitted with either the Rotax 912UL or Rotax 912ULS engines. Refer
to the manual supplied with the aircraft for the correct maintenance procedures.

Maintenance of the engine is in accordance with the Inspection schedule in Section
1 Inspections.

All defective engine components must be replaced with new parts obtained only
from the manufacturer or Rotax.

Any defects must be reported to the Manufacturer via Defect and Fault Reporting
Form included in this manual.

9 FLIGHT CONTROLS

9.1 General

Aileron control:
The control sticks actuate the ailerons through rods and bell cranks .

Wing flap control

Mechanical:
A lever located between the seats mechanically actuates the flaps through a rod and the
torque tube.
Four locking positions are provided:
- Cruise retracted
- Approach/ Landing extended 15/ 25/ 45

Unlocking is made possible by depressing the knob, which is located at the lever end.
Locking is obtained by releasing first the knob and moving the lever until the pawl engages
into the desired notch.

Electrical:
Optionally a flap linear actuator replaces the lever.
The actuator transmits the motion via a rod and the torque tube. Two limit switch units are
attached to the actuator.
The switch and the flap position indicator are located between the seats.

Elevators
Dual control sticks actuate the elevators through push pull tubes, a reversing lever and an
aft torque tube. The elevator control stops are located in the centre console between the
seats.

Rudder
Dual rudder pedals actuate the rudder through control cables and the nose wheel through
rods.The rudder control stops are located at the rudder fitting

Tab control
An elecLric piLch Lrim sysLem is conLrolled by swiLches on Lhe conLrol sLicks. Pressing Lhe fronL
swiLch lifLs Lhe Lrailing edge of Lhe Lrim Lab and resulLs in a piLch down Lrim, pressing Lhe rear
swiLch lowers Lhe Lrim Lab and resulLs in a piLch up Lrim. A panel-mounLed meLer indicaLes Lrim
posiLion.


Trim adjustment buttons Trim indicator

Instead of this version, two other options are possible:
1. A rocker switch and a position indicator located in the middle section below the instrument
panel
2. A knob in the middle section below the instrument panel actuates the trim tab. The
position of the knob indicates the position of the trim tab.


9.2 Flight controls and control surfaces
9.2.1 Aileron
If the control stick is fully actuated, the aileron deflection should be:
20 1 (115mm 6mm) Upwards
17 1 (94 mm 5 mm) Downwards

Overview aileron control

9.2.1.1 Checking operation and deflection of the aileron control assembly
- Control stick in neutral position: Ailerons have to be in line with the underside of the wing
Attention! It is possible that the ailerons are not in line with the glass-fibre wing tips!
There may be differences of 2 3 mm!
- Check the angle of the bellcrank (48- as shown in the drawing)
- Fully actuate the control stick in either direction and hold it
- Check that the aileron deflection angles are correct
- If required, re-adjust the swivel heads of the rod (Dia. 18 mm), or the deflection stops
- After that, snug down all detached nuts of the swivel heads / deflection stops
- Mark the nuts with torque seal

Aileron deflection


9.2.2 Wing flap control
Overview wing flap control

9.2.3 Elevators
Dual control sticks actuate the elevators through push pull tubes, a reversing lever and an
aft torque tube. The elevator control stops are located in the centre console between the
seats.
If the control stick is fully actuated, the elevator deflection should be:
25 1 ( 136mm 5mm) Upwards
20 1 ( 110mm 5mm ) Downwards
9.2.3.1 Checking operation and deflection of the elevator control assembly
- Control stick in neutral position: elevators have to be in line with the horizontal
stabilizer Attention! It is possible that the elevator tip is not in line with the stabilizer tip! There
may be differences of 1 2 mm!
- Fully actuate the control stick in either direction and hold it
- Check that the elevator deflection angles are correct
- If required, re-adjust the swivel heads of the rod (Dia. 12 mm), or the deflection stops
Overview elevator control


Elevator deflection


9.2.4 Rudder
Dual rudder pedals actuate the rudder through control cables and the nose wheel through
rods. The rudder control stops are located at the rudder fitting
If the pedal is fully actuated, the rudder deflection should be:
25 2 (145mm 10mm) To the left
25 2 (145mm 10mm) To the right

9.2.4.1 Operation and deflection check of the rudder control assembly

- Move the left pedal fully forward and hold it
- Check the rudder deflection angle
- Check for full contact of the stop and the adjustment screw
- Move the right pedal fully forward and hold it
- Check the rudder deflection angle
- Check for full contact of the stop and the adjustment screw
- If required, re-adjust the swivel heads of the rods of the nose wheel-steering
(Dia. 12 mm), or the deflection stops

Overview rudder control
Detail deflection stop


10 FUEL SYSTEM

10.1 General
Maintenance of the fuel system is in accordance with the Inspection schedule in
Section 1 Inspections.

All defective fuel system components must be replaced with new parts obtained only
from the manufacturer or Rotax.


Fuel indicator Fuel tank
Drain - valve
Carburetor
2-way cock
booster pump
Electric
(optionally)
M
Filter
Firewall
Filler neck
Engine driven pump
Engine


10.2 Fuel system
The aluminium fuel tank is located in front of the instrument-panel. It is connected by a line to
a 2-way valve whose positions are: On, Off
The valve is installed in the center pedestal. From the valve, the fuel is fed by a pipe to the
electric booster pump (optionally). A green warning light indicates to the pilot, that the booster
pump is in operation.
From the booster pump, fuel is forced through a filter to the engine-driven pump. From the
engine-driven pump the fuel is fed by a pipe to a T-fuel line splitter and from there to the
carburetors.
The tank is provided with a filler neck, which is located in front of the windshield. A drain valve
is located on the underside of the fuselage in the section of the left footstep.
A little tube is used as fuel indicator. It is located in the middle section of the instrument panel.
Optionally a fuel level gauge, located on the left side of the instrument panel, is used.

10.3 Fuel Flow Test

Mechanical Engine Pump

With engine running and with any back up pump turned off, bleed off fuel between
pump and carbs, restricting bleed off to maintain minimum 2.15 psi. Measure bleed
off at full throttle. This bleed off must be at least 25% of full throttle fuel consumption.

Back up Electric Pump

With engine stopped, run back up electric pump. Bleed off fuel as before maintaining
a minimum pressure of 2.15 psi.

Measure both bleed off amounts.

Full throttle fuel consumption for the 912 UL (80hp model) is 5.9 US Gallons/hr and 7.2
US Gallons/hr for the 912 ULS (100hp model).


11 PROPELLERS

The BREEZER can be supplied with different propellers :-

For approved propeller types you must consult the POH relevant to aircraft model.

All approved types have blades with ground-adjustable pitch and are set to the pitch
angles given in the relevant POH. This pitch angle is prescribed at a specific radius
from the point at which the blade exits from the hub.
The propellers have aluminium alloy hubs machined to close tolerances. This permits
secure clamping of the blade roots under the high centrifugal forces experienced by
the blades in service. Proper blade root securing bolt tension is essential to maintain
this security.

Maintenance of the propeller is in accordance with the Inspection schedule in


All defective propeller components must be replaced with new parts obtained only
from the manufacturer.

With composite propellers, minor damage to the external surface, such as a deep
scratch which breaches the outside fabric, can result in significant loss of strength and
a dangerous condition. For this reason it is important to inspect the blades carefully
before flight. Look particularly for scratches along the chord of the blade which may
have severed one or more yarns of fibre. When in doubt, seek expert advice.

Neuform propellers must be returned to Neuform in Germany for an inspection
every 500 hours or 2 years whichever comes first. Please refer to your propeller
operating manual.

Slight adjustment to the pitch of each of the above propellers may be necessary to
obtain the correct ground static rpm. An optical tachometer on the propeller is the
preferred method of measuring the engine speed.


Please see the technical data sheet section of the POH for further information.


12 UTILITY PARTS

Maintenance of utility parts is in accordance with the Inspection schedule in Section
1 Inspections.

All defective utility parts must be replaced with new parts obtained only from the
manufacturer.


Heater System

Cold air
intake
Firewall Exhaust heat exchanger
Cockpit heater tube
Heater valve assy Outside air vent
Heater valve knob
Push cold
Pull hot

13 INSTRUMENTS AND AVIONICS

Maintenance of instruments and avionics is in accordance with the Inspection
schedule in Section 1 Inspections.

All defective instruments and avionics must be replaced with new parts obtained only
from the manufacturer.



14 ELECTRICAL SYSTEM

Please refer to the schematics below.

Maintenance of the electrical system is in accordance with the Inspection schedule
in Section 1 Inspections.

All defective electrical components must be replaced with new parts obtained only
from Aerosport Ltd.


Appendix 1 Circuit Diagram Standard Installation

15 STRUCTURAL REPAIRS

Maintenance of the structural system is in accordance with the Inspection schedule in
No structural repairs can take place without the direct authorization of the manufacturer.
All structural repairs must be completed using only with new parts obtained only from the
manufacturer.
Never straighten bent tubes or bracket assemblies, replace with new parts only.
Never re-weld any parts.
Any defects must be reported to the Manufacturer via Defect and Fault Reporting Form
included in this manual.

16 JACKING THE AIRCRAFT

Either of the main wheels can be brought clear of the ground by one person lifting the wing
at the points shown below (At the main spar) The aircraft can then be chocked by placing a
wooden block under the bottom part of the stub axle.

The nose wheel is easily lifted by applying a load to the rear fuselage, just forward of the tail.
Where one person only is available, place weights on the tail, suitably padded to prevent
damage, until the nose wheel becomes light. Place a piece of timber under the tail skid,
then push the tail down on to it. Add further weights to the tail to stabilise the aircraft in this
attitude.

Main wheel jacking point


17 Cleaning

Maintenance of the wing and empennage is in accordance with the Inspection schedule in Section 1
Inspections.

Any defects must be reported to the Manufacturer via Defect and Fault Reporting Form included in
this manual.

Cleaning

The aircraft should be cleaned at the end of each day of flight. Insects and light dirt are best removed
using clear water, for more persistent dirt a mild detergent may be added to the water.
Depending upon type of operation and weather conditions the painted surfaces should be polished
and waxed at least once a year.
One should avoid parking the aeroplane for longer periods in the bright sunlight or in rain; if
necessary, use a tarpaulin to protect the aircraft from the weather.

Avoid the use of a pressure washer or garden hose as this can introduce water into places it shouldnt
go, (engine, fuel tank, pitot head, pilots seat).

Tightening torque
Main group Quantity Bolt diam. [mm] Nm lbs in lbs ft Remarks

Wing
Bracket - wing/fuselage 28 8 22 194,7 16,2 Lock nut
Rear spar attachment 2 10 40 354,0 29,5 Lock nut
Bellcrank 2 5 1,5 2,0 13,3 - 17,7 1,1 - 1,5 Do not compress the friction bearing!
Rod 32mm 4 6 9 79,6 6,6 Lock nut / Loctite
Aileron
Bearing 6 5 1,5 2,0 13,3 - 17,7 1,1 - 1,5 Do not compress the friction bearing!
Flap
Bearing 4 6 9 79,6 6,6 Do not compress the friction bearing!
Linkage - flap 2 6 9 79,6 6,6 Lock nut
Horizontal tail
Bracket - main spar 4 8 22 194,7 16,2 Lock nut
Bracket - rear spar 4 6 9 79,6 6,6 Lock nut
Elevator
Rudder
Cables 2 6 9 79,6 6,6 Lock nut
Adjustment screw 2 6 9 79,6 6,6 Lock nut / Loctite
Fuselage
Bearing aft torque tube 4 6 9 79,6 6,6 Lock nut

Lever - aft torque tube 2 6 9 79,6 6,6 Lock nut
Reversing lever 1 5 1,5 2,0 13,3 - 17,7 1,1 - 1,5 Do not compress the friction bearing!
Torque tube / flap 6 5 4,5 39,8 3,3 Lock nut
Safety belts 4 10 40 354,0 29,5 Lock nut
Lever 1 6 9 79,6 6,6 Lock nut
Flap lever grating 2 6 9 79,6 6,6 Lock nut
Cable guidance 12 4 2 17,7 1,5 Lock nut
Bracket - fuselage/wing 24 10 40 354,0 29,5 Lock nut
Bearing-Torsionsr 8 5 4,5 39,8 3,3 Lock nut
Stick 2 6 9 79,6 6,6 Do not compress the friction bearing!
Connecting tube / outward 2 6 1 8,8 0,7 Lock nut / Loctite
Connecting tube 2 6 9 79,6 6,6 Lock nut
Reversing lever 2 5 1,5 2,0 13,3 - 17,7 1,1 - 1,5 Do not compress the friction bearing!
Pedals 6 6 9 79,6 6,6 Lock nut
Piano wires 2 6 9 79,6 6,6 Lock nut
Landing gear
Attachment 10 8 22 194,7 16,2 Lock nut
Axle Lock nut
Engine mount
Attachment 5 8 22 194,7 16,2 Lock nut
Rotax mount ring 4 10 35 309,7 25,8 Lock nut


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18 FEEDBACK FORM

Aerosport Ltd. Defect and Fault Reporting
Form

Which details above should be used for communication Owner
Have any changes,modifications or repairs YES NO
have taken place to this aircraft since manufacture.
(If yes please state on a separate sheet the nature of all changes and include photographs)
When compiling your report please include, where applicable, the following :
1) Photocopy of the last logbook entry for aircraft and engine services.
2) When the problem occurs, how the problem manifests itsself, any damage caused by this problem,
any solutions you have tried to rectify the problem, any factors you think may have contributed
to this problem, any photographic evidence that supports your statements.
The more data you give us the quicker we can help you.
We take the safety and quality of our aircraft very seriously. We value any feedback that helps us promote flight safety and improve the quality of
our products. You will get a confirmation of reciept of your feedback form and any resulting action that is to be taken.
Action Taken

Action Confirmed to
Customer
Maintenance Org.
Date Received Confirmation sent by Date
Email
Tel
Post/Zip code
Country Country
Post/Zip code
Tel
Email
Name of Owner Maintenance Org.
Address Address

Total hours

A/C Model / Engine size
Aircraft Serial Number
Engine Serial Number
Propeller Make


19 APPENDIX A MANDATORY MODIFICATIONS


20 APPENDIX B - APPROVED OPTIONAL MODIFICATIONS
The installation of all optional modifications is to be inspected by an inspector from an Organisation approved
by the CAA for the purpose and an entry made in the appropriate logbook(s). Note that other approved
modifications may exist which are not listed here.


APPENDIX C - WEIGHING INFORMATION

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