Breezer Maintenance Manual

7/28/2019 Breezer Maintenance Manual

1/48

BREEZER Maintenance Manual Page 1 of 48 Issue 1

BREEZERLSA

Maintenance Manual

Issue 1


2/48


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.


3/48


1 CONTENTS

1 CONTENTS ....................................................................................................................................32 ISSUE AMENDMENTS...................................................................................................................43 GENERAL.......................................................................................................................................5

3.4 Drawing and Dimensions ....................................................................................................7

3.5 Equipment list .........................................................................................................................8 .....................................................................................................................................83.6 Sources for Spare parts......................................................................................................103.7 Consumable items..............................................................................................................103.8 Recommended Stocking List ...........................................................................................113.9 Engine Specifications.........................................................................................................123.10 Air pressure for tyres and shock absorber: ..............................................................123.11 Approved Oils/Coolants and Capacities................................................................123.12 Recommended fastener torque values ..................................................................123.13 Defect and Fault Reporting ........................................................................................12

4 Weight and Balance...............................................................................................................13 ......................................................................................................................................13 ...........................................................................................................................................13

5 INSPECTIONS ..............................................................................................................................155.1 Daily Inspection / Pre-flight Inspection ............ .............. ............ .............. ............. .............. .... 15Walk-around inspection........... ............ .............. ............. ............ .............. ............. .............. ............ ... 15Starting the engine.............. ............. .............. ............ ............. .............. ............. ............ .............. ....... 175.2 25 hour inspection...............................................................................................................185.3 50-Hour Inspection ..............................................................................................................185.4 100-Hour or Annual Inspection ........................................................................................19 ......................................................................................................................19

6 LANDING GEAR ........................................................................................................................207 Brake system..............................................................................................................................218 ENGINE ........................................................................................................................................239 FLIGHT CONTROLS....................................................................................................................249.2.1.1 Checking operation and deflection of the aileron control assembly ..........................269.2.3.1 Checking operation and deflection of the elevator control assembly........................ 28

10 FUEL SYSTEM ...............................................................................................................................3211 PROPELLERS ...............................................................................................................................3412 UTILITY PARTS ..............................................................................................................................3513 INSTRUMENTS AND AVIONICS ...............................................................................................3614 ELECTRICAL SYSTEM .................................................................................................................3715 STRUCTURAL REPAIRS...............................................................................................................3916 JACKING THE AIRCRAFT .........................................................................................................3917 Cleaning.......................................................................................................................................4018 FEEDBACK FORM ......................................................................................................................4519 APPENDIX A MANDATORY MODIFICATIONS ..................................................................4620 APPENDIX B - APPROVED OPTIONAL MODIFICATIONS ..................................................47


4/48


2 ISSUE AMENDMENTS

IssueNo.

Change/Description Date Signature

1 Initial Draft Issue

27/03/2006


5/48


6/48


7/48


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


8/48


9/48


10/48


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. LtdWolverhamton 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)


11/48


12/48


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.


13/48


14/48


$6#5!-?/4" @0>!/04"

%)'

%)' -4A->!/A/"6#5


15/48


16/48


17/48


18/48


19/48


5.4 100-Hour or Annual Inspection

- 4$'

/ G'

? H$

0 *'Perform 50 hours checks in accordance with ROTAX manual

%

= %$

A %!$"

C %

@ %$

-4 %

-- %'

( (

(

12. %

13. If installed: Replace cockpit carbon monoxide detector in accordance with

manufacturers instructions.

E $)

- I&

/ 5

?

0 %E

- *$

/

?


20/48


21/48


7 Brake system

The main landing gear wheels are provided with hydraulic disc-type brakes actuated by ahandlever 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


22/48


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 befooled 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.


23/48


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.


24/48


25/48


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 instrumentpanel

2. A knob in the middle section below the instrument panel actuates the trim tab. Theposition of the knob indicates the position of the trim tab.


26/48


27/48


Aileron deflection


28/48


9.2.2 Wing flap controlOverview wing flap control

9.2.3 ElevatorsDual control sticks actuate the elevators through push pull tubes, a reversing lever and anaft torque tube. The elevator control stops are located in the centre console between theseats.

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 horizontalstabilizer Attention! It is possible that the elevator tip is not in line with the stabilizer tip! Theremay 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

- After that, snug down all detached nuts of the swivel heads / deflection stops

- Mark the nuts with torque seal


29/48


30/48


31/48


32/48


33/48


34/48


35/48


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.

Any defects must be reported to the Manufacturer via Defect and Fault Reporting

Form included in this manual.

Heater System

Cold airintake

Firewall Exhaust heat exchanger

Cockpit heater tube

Heater valve assyOutside air vent

Heater valve knob

Push cold

Pull hot


36/48


37/48


38/48


39/48


15 STRUCTURAL REPAIRS

Maintenance of the structural system is in accordance with the Inspection schedule in

Section 1 Inspections.

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


40/48


41/48


42/48


43/48


44/48



45/48


46/48


47/48


48/48

Documents

Breezer Maintenance Manual