Page 1 Aeropro 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 20-12 ..........Upon receipt of the second and subsequent changes to this book, personal responsible for maintaining this publication in current status should ascertain that all previous changes have been received and incorporated. AEROPRO CZ Maintenance Manual March 21, 2020...
Page 3 Propeller 12-1 Utility systems 13-1 Instruments and instrument system 14-1 Electrical systems 15-1 Structural repair 16-1 Exterior painting 17-1 Wiring diagrams 18-1 Safety directives and safety monitoring system 19-1 A220 taildragger supplement 20-1 AEROPRO CZ Maintenance Manual March 21, 2020...
Page 4 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 for servicing Aeropro aircraft.
Page 5 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 Nm = 8.848 In.lb. 1 in.lb. = 0.113 Nm 1 ft.lb. = 1.356 Nm AEROPRO CZ Maintenance Manual March 21, 2020...
Page 6 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 steerable nose wheel. A two place, side by side seating configuration is standard.
Page 7 If a ballistic recovery system is installed from the factory, this is already included in the factory weight and balance calculation form. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 8 To get the total weight G you have to add weight G1 and G2. The center of gravity has to be calculated using this value. The C.G. is located at the distance (X) behind R.P. (leading edge) near the fuselage (see figure 1-6.).photo showing aircraft weighing Maintenance Manual AEROPRO CZ March 21, 2020...
Page 9 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 note: illustration below is for Aeropro aircraft prior to s/n 18106 - see individual aircraft documents for illustration appropriate for any specific aircraft Maintenance Manual...
Page 10 Aircraft leveling: Values Weighed: Main wheel Starboard side: rh = Port side: lh = Nose wheel pr = Result weight res = CG position [mm] [mm] [ % MAC ] Date: Performed by: Maintenance Manual AEROPRO CZ March 21, 2020...
Page 11 Maintenance Manual 1.9 Sources to purchase parts In figure 1-8. sources to purchase spare parts and disposable parts are given. When in doubt, ask your Aeropro distributor. Figure 1-8. Part description Sources Airframe and Engine Components……… Aeropro CZ Hlavní 439, 687 25...
Page 12 1-9. Details of where to purchase replacement parts are shown in figure 1- 8. When damage is found on any part of the aircraft please contact your Aeropro distributor when in any doubt about replacement or repair. No repairs must be done to any of the listed parts due to...
Page 13 (refer to Section 2). If in doubt about the airworthiness of the aircraft, it is strongly recommended to contact your Aeropro distributor. The aircraft must not be flown unless concerns about flight safety are resolved completely.
Page 14 Engine and engine compartment………………………….... 2-8 2.25 Upholstery and interior………………………..……………….. 2-9 2.26 Propeller……………………………………………..………….. 2-9 2.27 Wheels……………………………………………………..……. 2-9 2.28 Lubrication……………………………………………………………..... 2-9 2.29 Inspection…………………………..…………………………………… 2-10 2.30 Inspection requirements………..…………………………….. 2-10 Inspection charts………………………..……………………... 2-10 Inspection guide lines………………………..……………….. 2-10 III. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 15 Secure a tie-down rope (no chains or cables) to the exposed propeller shaft (between the cowling and the spinnner) and secure the opposite end of the rope to a ground anchor. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 16 Check battery and install. Check the oil sump has proper quantity of engine oil (Refer to Pilot Operating Handbook and/or Rotax Operator´s Manual for instructions). Service induction air filter and remove warning placard from propeller. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 17 "off" position (regular voltage 12.5 volts). If voltage does indicate 12.2 volts or less it has to be charged. Charging instructions can be found on the battery. If battery voltage is less than 11.8 volts a replacement battery may be required. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 18 Figure 2-1 - Rotax 912ULS engine installation Controls lever for carburetor heat Clip for elastic air tube Holder for oil cooler –one screw M5 Oil cooler Maintenance Manual AEROPRO CZ March 21, 2020...
Page 19 Maintenance Manual Figure 2-2 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 20 Bleed the brake system to remove entrapped air whenever there is a spongy response to the brake lever. Refer to paragraph 5.40 for filling and bleeding the brake system. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 21 The entire engine cowling may be removed to facilitate engine and interior cowl cleaning. Wash down the engine and components with a suitable solvent, then dry thoroughly with compressed air if available. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 22 Do not lubricate pulleys and bushings of control surface cables and rods. When Caution changing wheels it is recommended to lubricate wheel axles before reassembling to prevent them from corrosion and keep wheel changing easier. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 23 II. Inspection charts The latest-version AEROPRO INSPECTION CHECKLIST is always available at no charge from the U.S. Aeropro distributor – contact the distributor for the latest-version which is normally available on the distributor's web page at... www.aerotrek.aero/aerotrek-tips.htm As shown in the charts, there are items to be checked after the first 25 hours of service, each 100 hours and 200 hours, etc.
Page 24 Pilot Operating Handbook. During run-up, observe the 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.
Page 25 The cockpit skylights and doors are of polycarbonate (Lexan) material. The windshield is of acrylic (Plexiglass) material and is glued and riveting to the fuselage supported by aluminium plates to achieve the best possible aerodynamics and eliminate wind noise. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 26 Before attempting any scratch removal it is necessary to confirm the process and materials and tools being used with the Aeropro aircraft factory, the distributor, a qualified aviation technician, or a distributor of the acrylic material.
Page 27 Rivets 3.2 x 8 mm and 4.2 x 8 mm, lacquer and appropriate tools and equipment. 3.11.2 Parts required: windshield as required 3.11.3 Level of Maintenance: Heavy 3.11.4 Certification required: A&P Mechanic Maintenance Manual AEROPRO CZ March 21, 2020...
Page 28 To remove cabin doors (refer to figure 3-1) unlock and open the doors, detatch the support gas struts (3) from the door bracket (4). Withdraw safety pins from both rear hinges on the upper edge of the doors (2). Installation is carried out in reverse order. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 29 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 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 30 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 fiberglass component, attached to the fuselage at nine points. The seats are not adjustable. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 31 Loctite 243/242 (medium strength), cable ties, socket screw (M6 x 25 mm) + washer and retainer. 3.26.3 Level of maintenance: Heavy 3.26.4 Certification required: Aeropro CZ factory-authorized LSRM-A or A&P Mechanic Maintenance Manual AEROPRO CZ March 21, 2020...
Page 32 Maintenance Manual Figure 3-3 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 33 If the aircraft is to be equipped with the BRS system, follow the instructions in the rescue system installation manual. A special mounting kit, containing the bracket for the rocket motor and some miscellaneous parts can be obtained from the Aeropro CZ USA distributor. Figure 3-3. illustrates the installation of the rescue system in the aircraft.
Page 34 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 35 Maintenance Manual Figure 4-1 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 36 90° so that the leading edge is pointing downwards while moving the outboard end backwards till the wing is aligned with the fuselage tail. support wing at the root remove wing and lay on padded stand Maintenance Manual AEROPRO CZ March 21, 2020...
Page 37 Take care to ensure correct orientation of the washers, otherwise the folding mechanism of the wings will not operate properly and this may cause damage to the strut. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 38 / rear fuselage section. The elevator with its one piece leading edge (singular tube) is attached by five suspension points in total, with the drive located in the middle. All the rudder, stabilizer and elevator surfaces are fabric-covered. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 39 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 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 40 Unscrew and remove all struts and holders shown in figure 4-4 N.3, 4, 5, 6, 9 d. Disconnect and remove the elevator control rod. e. Remove elevator from fuselage For re-installation repeat the above in the reverse order Caution DO NOT REUSE SELF-LOCKING NUTS! Maintenance Manual AEROPRO CZ March 21, 2020...
Page 41 Maintenance Manual 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 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 42 The nose-wheel landing gear is constructed by welded steel tubes. The standard nose wheel is equipped with a 12x4 size tire. Larger tires and a larger front wheel are options. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 43 The webbed wheels having two aluminum flanges and a hub that are manufactured by an Aeropro supplier. The flanges are attached to the wheel hub by thru-bolts and nuts as shown in figure 5-2. During assembly of the main wheel the thru-bold nuts or capscrews, as applicable, shall be tightened evenly and torqued to the value specified in figure 5-2.
Page 44 3. remove cable ties securing the brake line distributor to the fuselage (accessible when baggage compartment is removed). 4. drain hydraulic brake fluid from brake lines. 5. disconnect hydraulic brake line at the brake line distributor. 6. hoist or jack aircraft in accordance with figure 5-1 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 45 1, 2, 3 -- 8mm bolts holding brake rotor onto inner wheel half 4. axle flange nut on the main wheel axle 5. 6x screw M6 (with 6x 6mm washers and 6mm nylock nuts) Maintenance Manual AEROPRO CZ March 21, 2020...
Page 46 5.10.1 Required Tools: 2x 10 mm wrench or 2x ratchets with 10mm sockets 5.10.2 Parts required: 6 x self-locking nut (M6) 5.10.3 Level of Maintenance: Light 5.10.4 Certification required: A&P or LSA Repairman Maintenance Maintenance Manual AEROPRO CZ March 21, 2020...
Page 47 Remove valve cover and deflate tire. Break tire beads loose from wheel rims. Injury can result from attempting to separate wheel halves with the tire inflated. Avoid damaging wheel flanges when breaking tire beads loose. Any scratches, gouges, or nicks may cause wheel failure. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 48 Figure 5-3 nose gear assembly assembly main bearing for holder of nose gear holder for shock absorber and stop of nose leg control lever of nose leg nose leg shock absorber wheel fairing Maintenance Manual AEROPRO CZ March 21, 2020...
Page 49 The hydraulic brake system consists of a master cylinder including a reservoir, located on the board panel. A brake hose connects the master cylinder to a distributor, located behind the cabin bulkhead. Two brake hoses run from the master distributor to each wheel brake cylinder. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 50 The brake master cylinder, located on the board panel, is activated by gently pulling on the brake lever postioned on the Instrument panel. A small reservoir is incorporated onto the master cylinder for the fluid supply. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 51 Use only DOT 4 brake fluid. 5.27 Hydraulic brake hoses All hydraulic hoses used for the brake system are flexible plastic hoses. All hoses provide appropriate connectors to provide an easy replacement. Maintenance Manual AEROPRO CZ 5-10 March 21, 2020...
Page 52 5.29 Removal To remove brake system from the wheel, refer to figure 5-2 and paragraphs 5.7 and 5.8 when the aircraft is equipped with Aeropro brakes. Drain hydraulic fluid from brake hoses prior to disconnecting the brake assembly. After the brake assembly is disconnected you can remove disc and brake linings from the assembly.
Page 53 More details on our web page at... http://www.aerotrek.aero/brake-bleeding-tips.htm Further information about servicing brake calipers is on an Aeropro photo-series on our web page at... http://www.aerotrek.aero/photos/brakes/service-brake-caliper.pdf Remove brake master cylinder filler plug and screw flexible hose with appropriate fitting into the filler hole at top of the master cylinder.
Page 54 6.17. Incorrect aileron travel Push-pull rods not adjusted Adjust in accordance with properly. paragraph 6.17. The control stick adjustment- Adjust in accordance with screws are not adjusted paragraph 6.17. properly. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 55 2. Rod between flaps and mixer 3. Controls lever 4. Mixer controls lever 5. Rod on the bottom 6. Rod for control of flap 7. Holder of controls Column 8. Controls lever 9. Flap lever 10. Controls stick Maintenance Manual AEROPRO CZ March 21, 2020...
Page 56 Aileron and flap control rods run from the control stick linkage joint through the fuselage to the aileron control surfaces through a series of bellcranks. The whole aileron control rod system requires no regular servicing. For details see Figure 6-2 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 57 Maintenance Manual Figure 6-2 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 58 If rigging was correct and the push-pull rod adjustment was not disturbed, it should not be necessary to rig system. Otherwise rig aileron system in accordance with paragraph 6.17. Caution Use new self-locking nuts and torque to the values given in Section 1 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 59 Check the maximum deflections of the ailerons and flaperons to make sure the correct range of movement can be reached for both the controls. (per wing/flaperon drawing below). Maintenance Manual AEROPRO CZ March 21, 2020...
Page 60 Maintenance Manual Maintenance Manual AEROPRO CZ March 21, 2020...
Page 61 Defective elevator hinges or Replace defective hinges or lubrication needed. lubricate per Section 2. Elevator fails to attain Interference beneath center Rig system in accordance with prescribed travel. cover or behind rear cabin paragraph 7.9. bulkhead. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 62 7.8 Removal and installation (refer to figure 7-1.) 8.8.1 Required Tools: head screwdriver, 10 mm wrench. 8.8.2 Parts required: 4 x self-locking nut (M6). 8.8.3 Level of Maintenance: Heavy 8.8.4 Certification required: A&P Mechanic or LSA Repairman Maintenance Maintenance Manual AEROPRO CZ March 21, 2020...
Page 63 Maintenance Manual Figure 7-1 1. controls stick Maintenance Manual AEROPRO CZ March 21, 2020...
Page 64 Check for centered positon of control stick. If required, adjust stick center position at the aft end of push-pull tube and secure with Loctite 243. Check elevator travel as outlined in figure 1-1. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 65 Unconnected cable on the trim tab Check all controls road lever Incorrect trim tab Inside in the bowden is dirt Check and clean cable and lubricate travel. Controls cable is rusty Removal cable and clean bowden and lubricate Maintenance Manual AEROPRO CZ March 21, 2020...
Page 66 Maintenance Manual 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 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 67 Unscrew the screws of the fork at the end of the cable on the elevator trim. See 3 pict. 8-2 Release the cable and unscrew the securing screw as seen at 45 pict. 8-1 Carefully remove the lever from the cockpit area considering the trim control cable. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 68 Check for correct movement of trim tab. Pushing the control lever to the "forward" and checking the Trim Tab moves ”downward”. Always use a new cotter pin when reestablishing the connection of push-pull rod at Note the trim tab bracket. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 69 Lubricate copper bushings lubrication. of nose gear strut. Lost motion between Insufficient cable tension. Adjust cable tension in rudder pedals and rudder. accordance with paragraph 10.11. Incorrect rudder travel. Incorrect rigging. Rig system Maintenance Manual AEROPRO CZ March 21, 2020...
Page 70 9.7.4 Certification required: A&P Mechanic or LSA Repairman Maintenance Disconnect cables from rudder. Remove all hinge bolts upward to disengage Reverse preceding steps for installation. Rig system in accordance with applicable paragraph in this section. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 71 9.11 Rudder centering device and rudder trim adjustment See information about the Aeorpro Rudder-Centering Device and rudder trim adjustment on our Aerotrek-tips web page at... www.aerotrek.aero/aerotrek-tips.htm -- or go direct to the .pdf file with information at... www.aerotrek.aero/aerotrek-tips/aeropro-rudder-trim-adjustment.pdf Maintenance Manual AEROPRO CZ...
Page 72 Magneto removal and installation …………………………. 10.32 10-17 Magneto check……………………………………………….. 10.33 10-17 Spark plugs …………………………………………………… 10.34 10-17 10.35 Engine controls………………………………………………………. 10-17 10.36 Rigging…………………………………………………………. 10-18 Throttle control………………………………………... 10.37 10-18 Choke control…………………………………………. 10.38 10-19 Carburetor heat control……………………………… 10.39 10-19 Maintenance Manual AEROPRO CZ 10-1 March 21, 2020...
Page 73 Take care to disconnect the electrical wiring to the landing light in lower cowling (if installed N.7) when removing the lower cowling. When reinstalling the cowlings – reverse the above process. Maintenance Manual AEROPRO CZ 10-2 March 21, 2020...
Page 74 10.4 Repair 11.4.1 Required Tools: As required 11.4.2 Parts required: Epoxy Resin, carbon fiber tape, rovings, fabrics. 11.4.3 Level of Maintenance: Heavy 11.4.4 Certification required: A&P Mechanic or LSA Repairman Maintenance Maintenance Manual AEROPRO CZ 10-3 March 21, 2020...
Page 75 Min…………………………………………………… -13° F Fuel pressure: Max………………………………………… 5.8 psi Min............2.2 psi Electric starter……………………………………………… 12V, 0.6 kw Generator…………………………………………………… 12V, 20A Spark plugs, NGK............DCPR8E Spark plug gap…………………………………….. 0.027 in Torque..............176 in/lb Maintenance Manual AEROPRO CZ 10-4 March 21, 2020...
Page 76 Test harness cables. If persistent perform top overhaul. Small air leak into induction system. Tighten connections or replace damaged parts. Defective engine. Check compression and listen for unusual engine noises. Engine repair is required. Maintenance Manual AEROPRO CZ 10-5 March 21, 2020...
Page 77 Refer to section 2 for seasonal grades. Oil regulator flap closed. Set oil regulator flap to open position. Prolonged high speed operation on Hold ground running above 2500 ground. rpm to a minimum. Maintenance Manual AEROPRO CZ 10-6 March 21, 2020...
Page 78 Place all instrument switches and fuel valves in the OFF position. Remove engine cowlings Disconnect the battery cable(s) and insulate the cable terminal(s) as a safety precaution. Disconnect all wiring at the terminals on the right hand side of the firewall. Maintenance Manual AEROPRO CZ 10-7 March 21, 2020...
Page 79 Unscrew engine to mount attachment screws and remove engine mount. Carefully guide the disconnected components away from the engine assembly. 10.9 Cleaning The engine may be cleaned with a suitable solvent, then dried thoroughly. Maintenance Manual AEROPRO CZ 10-8 March 21, 2020...
Page 80 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 be new parts. Maintenance Manual AEROPRO CZ 10-9 March 21, 2020...
Page 81 12. Shaped washer 13. Shelf-locking nut M8 Hoist engine assembly at the inlet manifold on top of the engine. Install engine to the engine mount using M12 screws (refer to N.6 figure 10-3) Maintenance Manual AEROPRO CZ 10-10 March 21, 2020...
Page 82 26 Nm/230 in.lb. Service engine with proper grade and quantity engine oil. Refer to engine manufacturers manual or Aeropro A240 Pilot Operating Handbook. Make sure all switches are in the OFF position, and connect battery cable(s) to battery.
Page 83 Perform engine mount repair as outlined in Section 18. The mount should be painted with a heat- resistant grey enamel after welding or whenever the original finish has been removed or degraded. Maintenance Manual AEROPRO CZ 10-12 March 21, 2020...
Page 84 Oil pump suction tube screen Engine overhaul required. plugged or internal oil leak. Secondary result of high oil Observe oil temperature gauge temperature. for high indication. Determine and correct reason for high oil temperature. Maintenance Manual AEROPRO CZ 10-13 March 21, 2020...
Page 85 Check for proper oil level in the oil tank, and add oil if necessary. Again check for oil leakage after the engine has been run at a high power setting (preferably following a flight around the field). Maintenance Manual AEROPRO CZ 10-14 March 21, 2020...
Page 86 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 Maintenance Manual AEROPRO CZ 10-15 March 21, 2020...
Page 87 (refer to paragraph 10.26). After removing the protection cover at the rear of the engine, access to the magnetos is available. Replace the magnetos in accordance with the Rotax maintenance manual. For re-installation, reconnect all items removed for access to the magnetos. Maintenance Manual AEROPRO CZ 10-16 March 21, 2020...
Page 88 10.35 Engine controls Engine controls designed of the conventional push-pull type include the throttle, choke and carburetor heat controls. The engine controls are equipped with position-locking devices which prevent vibration-induced “creeping” of the controls. Maintenance Manual AEROPRO CZ 10-17 March 21, 2020...
Page 89 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 Maintenance Manual AEROPRO CZ 10-18 March 21, 2020...
Page 90 Pull the carburetor heat control to on-position. Check that both the arms on the carburetor heat achieve their maximum travel. If required readjust the controls at the locknut on the carburetor heat arm. Maintenance Manual AEROPRO CZ 10-19 March 21, 2020...
Page 91 This heated air is used to heat the aircraft cabin. A tail pipe from the muffler routes exhaust gases outboard through the lower cowling. The complete exhaust system is manufactured from stainless steel. Maintenance Manual AEROPRO CZ 10-20 March 21, 2020...
Page 92 100-hour of operation. In addition, an inspection of the exhaust system should be performed anytime exhaust fumes are detected in the cabin area. Maintenance Manual AEROPRO CZ 10-21 March 21, 2020...
Page 93 In humid areas, fuel and oil should be checked frequently and drained of condensed moisture. Hardware (bolts and nuts) should be periodically treated with a good corrosion-preventative (such as ACF-50 or other good products). Maintenance Manual AEROPRO CZ 10-22 March 21, 2020...
Page 94 Maintenance Manual Maintenance Manual AEROPRO CZ 10-23 March 21, 2020...
Page 95 Take care to disconnect the electrical wiring to the landing light in lower cowling (if installed N.7) when removing the lower cowling. When reinstalling the cowlings – reverse the above process. Maintenance Manual AEROPRO CZ 10a-1 March 21, 2020...
Page 96 If cracks are detected in the carbon fiber cowl segments, they may be repaired using L285 Epoxy Resin or similar (R&G L20), reinforcing with suitable carbon fiber fabrics. Follow the instructions on the container for a successful completion of the repair. Maintenance Manual AEROPRO CZ 10a-2 March 21, 2020...
Page 97 Electric starter..............12V, 0.6 kw ..12V, 0.7 kw Generator................12V, 20A ....12V, 20A Spark plugs................NGK DCPR8E ..ND X27EPR-U9 Spark plug gap............0.027 in ....0.027 in Spark plug torque............176 in/lb ..... 176 in/lb Maintenance Manual AEROPRO CZ 10a-3 March 21, 2020...
Page 98 Test harness cables. If persistent perform top overhaul. Small air leak into induction system. Tighten connections or replace damaged parts. Defective engine. Check compression and listen for unusual engine noises. Engine repair is required. Maintenance Manual AEROPRO CZ 10a-4 March 21, 2020...
Page 99 Oil regulator flap closed. Set oil regulator flap to open position. Prolonged high speed operation on Hold ground running above 2500 ground. rpm to a minimum. Low oil pressure. Low oil supply. Replenish. Maintenance Manual AEROPRO CZ 10a-5 March 21, 2020...
Page 100 Cylinder wall-coating worn. Replace cylinder and rings. Intake valves guides worn. Top overhaul. Valves seats and faces worn. Top overhaul. Piston rings excessively worn. Top overhaul. Valves sticking in guides. Top overhaul. Maintenance Manual AEROPRO CZ 10a-6 March 21, 2020...
Page 101 Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10.25 Engine fuel system - refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals Maintenance Manual AEROPRO CZ 10a-7 March 21, 2020...
Page 102 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 Rigging - refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10.37 Throttle control - refer to this section in main Maintenance Manual plus all relevant information in...
Page 103 10.49 Dusty conditions - refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals 10.50 Sea coast and humid areas - refer to this section in main Maintenance Manual plus all relevant information in the Rotax 914 engine manuals Maintenance Manual AEROPRO CZ 10a-9 March 21, 2020...
Page 104 Maintenance Manual 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 Maintenance Manual AEROPRO CZ 10a-10 March 21, 2020...
Page 105 Maintenance Manual Maintenance Manual AEROPRO CZ 10a-11 March 21, 2020...
Page 106 Maintenance Manual Maintenance Manual AEROPRO CZ 10a-12 March 21, 2020...
Page 107 Maintenance Manual Maintenance Manual AEROPRO CZ 10a-13 March 21, 2020...
Page 108 Residual fuel draining from lines and hose constitutes a fire hazard. Use caution to prevent the spillage of fuel when lines or hoses are disconnected. Cap any open fuel lines and cover connection points to prevent thread damage and the entrance of any foreign matter. Maintenance Manual AEROPRO CZ 11-1 March 21, 2020...
Page 109 12.7.3 Level of Maintenance: Heavy 12.7.4 Certification required: A&P Mechanic or LSA Repairman Maintenance Push up sump drain valve, to drain all fuel from the tanks. (Observe precautions outlined in paragraph 11.3.) Maintenance Manual AEROPRO CZ 11-2 March 21, 2020...
Page 110 To install header tank, reverse the preceding steps. Be sure grounding is secure in accordance with paragraph 11.3. Apply appropriate liquid sealant to the threads of drain valve and fuel line connector Note while reassembling the system. Figure 11-1 Maintenance Manual AEROPRO CZ 11-3 March 21, 2020...
Page 111 For reconnection of fuel line to firewall a new fuel line fitting has to be used, to avoid Caution leakage. Remove screws attaching shut-off valve. Withdraw shut-off valve assembly from the holder on the fuselage. Disconnect fuel lines from shut-off valve. Reverse the preceding steps for installation. Maintenance Manual AEROPRO CZ 11-4 March 21, 2020...
Page 112 NOTE: The latest version Inspection Checklist is always available on our Aerotrek-tips web page at... www.aerotrek.aero/aerotrek-tips.htm Maintenance Manual AEROPRO CZ 11-5 March 21, 2020...
Page 113 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. Check also the jet provided in the return hose fitting for clean and unblocked condition. Maintenance Manual AEROPRO CZ 11-6 March 21, 2020...
Page 114 Section 11A - supplementary Section 11A for 914UL engine installations Fuel system This section includes some information for the optional Rotax 914UL turbo-charged engine. The Rotax 914UL engine is a sophisticated engine and our aircraft are delivered with the Rotax 914 Operators Manual with a great deal of essential information for operation and maintenance.
Page 115 11.3 Precautions There are certain general precautions and rules concerning the fuel system which Note should be observed when performing the operations and procedures in this section. These are as follows. During all fueling, defueling, tank purging, and tank repairing or disassembly, ground the aircraft to a suitable ground stake.
Page 116 11.5 Fuel tank 11.6 Description - aircraft and with 914 engine installation The fuel system includes two aluminium wing tanks of 10.6 gal fuel capacity each, a special plastic (manufactured for contact with gas) header tank of 1.1 gal capacity, a drain valve, three fuel valves, a fuel filter, with the 914 engine having dual electric fuel pumps, and connecting lines.
Page 117 Blow gently into tube to slightly pressurize the tank. If air can be blown into tank, vent line is open. 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.
Page 118 11.16 Fuel distribution system (refer to Figure 11-2.) A fuel distributor is installed to provide fuel for both carburetors. The fuel distributor is located on top of the engine. Pressurized fuel from the Rotax 914 fuel pumps is routed to both carburetors while surplus of fuel flows back to the fuel tank through a return hose.
Page 119 Remove clamp securing distributor block to engine. Disconnect hose fittings from the distributor. Caution Remember position of return hose fitting for reinstallation. Reverse preceding steps for reinstallation (Observe precautions outlined in paragraph 11.3.). Always use new copper-washer sealing for reinstallation of hose fittings and new Caution hose clamps for hose connections.
Page 120 (11) and will be free by removal of the bolts as the propeller is removed. Remove bolts and pull propeller forward to remove. Use care to avoid damage to bulkheads as propeller is removed. Maintenance Manual AEROPRO CZ 12-1 March 21, 2020...
Page 121 Maintenance Manual Figure 12-1 note: sample prop is shown - Aeropro CZ aircraft use various composite props... 1. Spinner 6. Self-locking nylock nut 2. Propeller 7. Washer 3. Mounting bolts M8 8. Screw M6 (varies with different propellers) 4. Rear bulkhead 9.
Page 122 13.6 Removal, installation and repair 13.6.1 Required Tools: screwdrivers 13.6.2 Parts required: hoses and hose clamps as required. 13.6.3 Level of Maintenance: Light 14.6.4 Certification required: LSA Repairman Maintenance or Owner Maintenance Manual AEROPRO CZ 13-1 March 21, 2020...
Page 123 Each side has Independent shut-off valves. The shut-off valves are located on the top of instrument panel and are operated by rotating the valve shut-on/off disc anywhere from the fully open to fully closed position. Maintenance Manual AEROPRO CZ 13-2 March 21, 2020...
Page 124 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. Maintenance Manual AEROPRO CZ 13-3 March 21, 2020...
Page 125 Whether replacement is to be with a new instrument, an exchange one, or original instrument is to be repaired must be decided on basis of individual circumstances. AEROPRO CZ 14-1 March 21, 2020...
Page 126 To remove the stationary panel proceed as follows: Disconnect battery leads and remove instrument panel. Loosen and unscrew the following controls devices:- throttle, carburator heat, brake, cockpit heating and choke. AEROPRO CZ 14-2 March 21, 2020...
Page 127 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 AEROPRO CZ 14-3 March 21, 2020...
Page 128 14.8 Pitot and static system (refer to figure 14-2.) 14.9 Description The pitot system conveys ram air pressure to the airspeed indicator. The static system uses cockpit air and there is not a separate static line installed in these aircraft. AEROPRO CZ 14-4 March 21, 2020...
Page 129 Pitot tube obstructed, leak or Test pitot tube and line for leaks or indication (normal altimeter and obstruction in pitot line. obstructions. Blow out tube and line, vertical speed). repair or replace damaged line. AEROPRO CZ 14-5 March 21, 2020...
Page 130 Check other instruments and speed indicator installations. system plumbing for leaks. Blow out lines. 14.18 Trouble shooting - Vertical speed indicator Trouble Probable Cause Remedy Instrument fails to operate. Static line plugged. Check port for obstruction. AEROPRO CZ 14-6 March 21, 2020...
Page 131 EIS will warn the pilot by means of a warning light. 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...
Page 132 14.26 Slip indicator. A slip indicator is provided on the left panel or is incorporated into an electronic EFIS. The slip indicator needs no servicing at all. AEROPRO CZ 14-8 March 21, 2020...
Page 133 Description…………………………………………….. 15-5 Trouble shooting……………………………………… 15.33 15-6 Navigation lights……………………………………... 15.34 15-7 Description…………………………………….. 15.35 15-7 Removal and installation……………………... 15.36 15-7 Anti collision strobe light……………………………. 15.37 15-7 Description…………………………………….. 15.38 15-7 Removal and installation……………………... 15.39 15-7 Maintenance Manual AEROPRO CZ 15-1 March 21, 2020...
Page 134 The keyed switch is located below the magneto switches. The keyed switch operates the battery and alternator system. The switch, when operated, connects the battery to the engine wiring system, activating the power systems. Maintenance Manual AEROPRO CZ 15-2 March 21, 2020...
Page 135 (regulator diodes, radio protection diodes and radio transistors). Disconnect the cable from the positive terminal of the battery. Lift the battery out of the battery box. To replace the battery, reverse preceding steps. Maintenance Manual AEROPRO CZ 15-3 March 21, 2020...
Page 136 Battery should in general be charged only when disconnected from the aircraft. Charge battery in accordance to the charging instructions found on the battery. For methods to trickle- charge/maintain the battery charge without necessarily removing the battery from the aircraft, contact the Aeropro distributor. Maintenance Manual AEROPRO CZ...
Page 137 The aircraft lighting system consists of navigation lights, a pair of small landing lights, anti- collision strobe lights and some lighted instruments. All electrical switches to control the lighting system are located on the switch panel as outlined in paragraph 15.6. Maintenance Manual AEROPRO CZ 15-5 March 21, 2020...
Page 138 Repair or replace wiring. Defective switch. 3. Check voltage at lights with master switch and instrument light switch ON. Should read battery voltage. Replace switch. Lamps burned out. Inspect lamps, replace lamps. Maintenance Manual AEROPRO CZ 15-6 March 21, 2020...
Page 139 To remove the cigarette lighter socket, proceed as outlined below. Disconnect the battery leads and insulate as safety precaution. Disconnect the wiring from the receptacle, note wiring for reinstallation. Unscrew and remove the receptacle Reverse preceding steps for reinstallation. 15.46 Alterations Maintenance Manual AEROPRO CZ 15-7 March 21, 2020...
Page 140 1. Emergency locator transmitter ( ELT ) 2. Antenna cable 3. Antenna (2016 and newer - on top of fuselage) 5. landing/taxi light 4. Switch for landing light 6. cable for landing light Maintenance Manual AEROPRO CZ 15-8 March 21, 2020...
Page 141 Whelen LED position lights…………………........0.5 (approx.) EIS electronic engine instrument…………………......Optional equipment (running load) transponder…………………..............… COM radio……………………………........…………. 0.5 - 2.5 Items not considered as part of running load External receptacle……………………………………......max. 4.0 Landing light……………………………………………......Maintenance Manual AEROPRO CZ 15-9 March 21, 2020...
Page 142 16.6 Damages of larger extent. When damages of larger extent is found, we recommend to consult the manufacturer. Always replace parts and components with parts and components of the same material specification. Maintenance Manual AEROPRO CZ 16-1 March 21, 2020...
Page 143 Avoid thinner coming in contact with ABS parts or windows. These areas should be Caution cleaned with mild soap and water. Do not use strong solvents such as xylol, toluol, or lacquer thinners. Maintenance Manual AEROPRO CZ 17-1 March 21, 2020...
Page 144 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. Maintenance Manual AEROPRO CZ 18-1 March 21, 2020...
Page 145 19.1 General Safety directives are issued by Aeropro CZ, to ensure the safe operation of the aircraft if required. Safety directives are issued in accordance to the applicable ASTM continued airworthiness specification. Service Directives are considered as mandatory tasks in order to maintain a condition of safe operation and compliance with the applicable original ASTM design specification.
Page 146 19.2 Operational safety monitoring system An operational safety monitoring system is maintained by Aeropro CZ to ensure the continued airworthiness of your aircraft. To receive and evaluate all safety of flight and service difficulty reports a feedback form is provided with this maintenance manual.
Page 147 Manual MAINTENANCE MANUAL Supplement for A220 taildragger Aeropro CZ - A220 Maintenance Manual AEROPRO CZ March 21, 2020...
Page 148 Maintenance Manual 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. Maintenance Manual 20-1 AEROPRO CZ March 21, 2020...
Page 149 B = (M x (L- L ) / M [ mm] X = B + 50 = [ mm ] X = (X x 100) / 1300 = [ %MAC ] Date: Performed by: Maintenance Manual 20-2 AEROPRO CZ March 21, 2020...
Page 150 Maintenance Manual Figure 2-2 Maintenance Manual 20-3 AEROPRO CZ March 21, 2020...
Page 151 Incorrect tire inflation Inflate to pressure specified in figure 1-1. Tires wears excessively Incorrect tire inflation Inflate to pressure specified in figure 1-1. Dragging brakes Refer to paragraph 5.28. Wheel bearing damaged Install new part(s) Maintenance Manual AEROPRO CZ March 21, 2020...
Page 152 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...
Page 153 Heavy 5.6.4 Certification required: A&P Mechanic or LSA Repairman Maintenance Repair of main gear is possible only in Aeropro company or an Aeropro-authorized company which has required experience and complete technology for welding. 5.7 Main Wheel Removal 5.7.1 Required Tools: 27mm socket (for axle nut), 13mm wrench, etc.
Page 154 Uneven or improper torque of thru-bolt nuts can cause failure of bolts, with resultant Caution wheel failure. Do not use aircraft hydraulic fluid, doing so will cause damage to the cylinder seals. Caution Only DOT 4 automobile brake fluid must be used. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 155 Carefully inspect bearings for damage and discoloration or noises when rotating. Do not try to re-lubricate the sealed bearings. If in doubt about bearing condition, replace bearings. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 156 A&P Mechanic or LSA Repairman Maintenance Insert thru-bolts through wheel half. Position tire on second wheel half Place one wheel half to position on other wheel half. Apply a light force to bring wheel halves together. Maintenance Manual AEROPRO CZ March 21, 2020...
Page 157 Since the tail wheel steering 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.
Page 158 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.

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