FLIGHT DESIGN CTLS Series Guida di riferimento

CTLS

LSA

SERIAL NUMBER:_______________

Maintenance and Inspection Procedures Manual

THIS DOCUMENT AND THE TECHNICAL DATA HEREON DISCLOSED ARE PROPRIETARY TO FLIGHT DESIGN AND SHALL

NOT BE USED, RELEASED, OR DISCLOSED IN WHOLE OR IN PART WITHOUT EXPRESS WRITTEN PERMISSION FROM

FLIGHT DESIGN

Maintenance and Inspection Procedures Manual

Type:

Series:

CTLS

LSA Page: ii

AF 04800001 Revision No. 4 Date: 02 Jan 2009

REVISION STATUS

Rev Pages Date Chapter completed

1 All Jan 10, 2008 All Vasyl Sys

- System of pages numbering changed

- Formatting (page breaks) partially changed

All “or higher grade of certificate” added to

“Repairman, Light Sport Aircraft-Maintenance

(RLSA-M).”

1-5 1.6 Equipment List updated

1-10–1-11 1.13 changed

1-12 1.15 “Owner’s operational” changed to “Service”

8-1 8 changed

8-2 8.5.2 changed

8-2 8.5.3 changed

8-3 – 8-4 8.5.10 – 8.5.16 added

8-5 8.6 changed

Apr 01, 2008

App. 1 updated

Vasyl Sys

1-1 1 Updated with Warning

1-2 1.3 Warning deleted

1-8 1.9 Operating speeds and limits updated

2-11–2-12 2.9 updated with “Lubricate rod end bearings”

3-1 3 page numbers corrected in the table

3-32–3-40 3.3.2 updated

5-2 5.1 updated

8-3 8.5.9 C9997199F Switch panel EK 10228 deleted

8.5.10 Garmin SL30 added

8.5.11 changed

8-4

8.5.13 changed

All Number of document changed

Vasyl Sys

1 App. I changed to App. V

17 App. I changed to App. V

1-1 1 updated

1-1 1.2 added contact

1-6 1.6 text added

1-9 1.9 “Engine specification” deleted

1-9 1.10 “Minimum single pilot weight” deleted

3-10 3.1.2.6 changed

8-3 8.5.6 Vertical Speed Indicator (Variometer)

deleted

9-1 9. deleted incorrect drawing number

11-1 11.1 updated

2-4 2.3 – 2.10 updated

3-11-3-21

Sep 14, 2008

3.2-3.2.1.9 “Stabilizer” moved to 3.4.4.

Vlada Luzhnykh

3-1 – 10-5 Allocation of Level of Maintenance and Level of

Certification detailed and adapted. Requirements

for Flight Design Training reviewed. Linguistic

clarifying corrections included throughout the

whole procedures.

O. Reinhardt

1-1 Address of Flight Design is changed4

AІV-1-AІV-14

02 Jan 2009

Added Appendix IV MATCO Brake System

S. Pilipenko

Maintenance and Inspection Procedures Manual

Type:

Series:

CTLS

LSA Page: iii

AF 04800001 Revision No. 4 Date: 02Jan 2009

LIST OF EFFECTIVE PAGES

CHAPTER CHAPTER CHAPTER CHAPTER

PAGES PAGES PAGES PAGES

REV REV REV REV

1-1 4 4-17 3 4-61 3 8-5 3

1-2 3 4-18 3 4-62 3 8-6 3

1-3 3 4-19 3 4-63 3 8-7 3

1-4 3 4-20 3 4-64 3 8-8 3

1-5 3 4-21 3 4-65 3

(cont.)

8-9 3

1-6 3 4-22 3 4-66 3 9-1 3

1-7 3 4-23 3 4-67 3 9-2 3

1-8 3 4-24 3 4-68 3 9-3 3

1-9 3 4-25 3 4-69 3 9-4 3

1-10 3 4-26 3 4-70 3

9-5 3

1-11 3 4-27 3 4-71 3 10-1 3

1-12 3 4-28 3 4-72 3 10-2 3

1-13 3 4-29 3 4-73 3 10-3 3

2-1 3 4-30 3 4-74 3 10-4 3

2-2 3 4-31 3 4-75 3

10-5 3

2-3 3 4-32 3 4-76 3 AI-1 3

3-1 3 4-33 3 4-77 3 AI-2 3

3-2 3 4-34 3 4-78 3

App. I

AI-3 3

3-3 3 4-35 3 4-79 3 AII-1 3

3-4 3 4-36 3 4-80 3

App. II

AII-2 3

3-5 3 4-37 3 4-81 3 App. III AIII-1 3

3-6 3 4-38 3 4-82 3 App. IV AIV-1-

AIV-14 4

3-7 3 4-39 3 4-83 3

3-8 3 4-40 3 4-84 3

3-9 3 4-41 3 4-85 3

3-10 3 4-42 3

(cont.)

4-86 3

3-11 3 4-43 3 5-1 3

3-12 3 4-44 3 5-2 3

4-1 3 4-45 3 5-3 3

4-2 3 4-46 3

5-4 3

4-3 3 4-47 3 6-1 3

4-4 3 4-48 3 6-2 3

4-5 3 4-49 3 6-3 3

4-6 3 4-50 3 6-4 3

4-7 3 4-51 3 6-5 3

4-8 3 4-52 3 6-6 3

4-9 3 4-53 3 6-7 3

4-10 3 4-54 3 6-8 3

4-11 3 4-55 3

6-9 3

4-12 3 4-56 3 7 7-1 3

4-13 3 4-57 3 8-1 3

4-14 3 4-58 3 8-2 3

4-15 3 4-59 3 8-3 3

4-16 3

(cont.)

4-60 3

8-4 3

Maintenance and Inspection Procedures Manual

Type:

Series:

CTLS

LSA Page: iv

AF 04800001 Revision No. 3 Date: 14 Sep 2008

TABLE OF CONTENTS

1General............................................................................................................................................ 1-1

1.1 Manufacturer............................................................................................................................. 1-1

1.2 Contact in USA.......................................................................................................................... 1-1

1.3 Care and cleaning of your CT................................................................................................... 1-2

1.4 Views, dimensions .................................................................................................................... 1-3

1.5 Construction Materials .............................................................................................................. 1-5

1.6 Equipment List .......................................................................................................................... 1-6

1.7 Source to Purchase Parts......................................................................................................... 1-7

1.8 List of Disposable Replacement Parts...................................................................................... 1-7

1.9 Weight and Balance Information............................................................................................... 1-8

1.10 Tire Inflation Pressure............................................................................................................. 1-10

1.11 Approved Fluids and Capacities ............................................................................................. 1-10

1.12 Recommended Fastener Torque Values and Bolts Installation ............................................. 1-11

1.13 General Safety Information..................................................................................................... 1-12

1.14 Instructions for Reporting Possible Safety of Flight Concerns Found During Inspection /

Maintenance............................................................................................................................ 1-13

2Minimum Levels of Certification:...................................................................................................... 2-1

2.1 General ..................................................................................................................................... 2-1

2.2 Levels of certification................................................................................................................. 2-1

2.3 Required certification level for maintenance procedures.......................................................... 2-2

3Aircraft Inspections.......................................................................................................................... 3-1

3.1 Aircraft Records ........................................................................................................................ 3-2

3.2 Run-up ...................................................................................................................................... 3-3

3.3 Post-Run-up.............................................................................................................................. 3-4

3.4 Propulsion System.................................................................................................................... 3-5

3.5 Fuselage ................................................................................................................................... 3-6

3.6 Wings ........................................................................................................................................ 3-7

3.7 Empennage............................................................................................................................... 3-8

3.8 Landing Gear ............................................................................................................................ 3-9

3.9 Cabin and Baggage Compartment ......................................................................................... 3-10

3.10 Inspection Completion............................................................................................................. 3-12

4Structures ........................................................................................................................................ 4-1

4.1 Wing.......................................................................................................................................... 4-1

4.1.1 Wing Structure..................................................................................................................... 4-1

4.1.2 Wing Installation and Removal............................................................................................ 4-2

4.1.2.1 Tools Required............................................................................................................ 4-2

4.1.2.2 Parts and Materials Required ..................................................................................... 4-2

4.1.2.3 Type of Maintenance .................................................................................................. 4-2

4.1.2.4 Minimum Level of Certification.................................................................................... 4-2

4.1.2.5 Wing Installation.......................................................................................................... 4-2

4.1.2.6 Wing Removal............................................................................................................. 4-9

4.1.2.7 Verification Required................................................................................................... 4-9

4.2 Landing Gear .......................................................................................................................... 4-10

4.2.1 Nose Landing Gear............................................................................................................ 4-10

4.2.1.1 Tools Required.......................................................................................................... 4-10

4.2.1.2 Materials Required.................................................................................................... 4-10

4.2.1.3 General ..................................................................................................................... 4-10

4.2.1.4 Inspections................................................................................................................ 4-11

4.2.1.4.1 Type of Maintenance........................................................................................... 4-11

4.2.1.4.2 Minimum Level of Certification ............................................................................ 4-11

4.2.1.4.3 Visual Inspection ................................................................................................. 4-11

4.2.1.4.4 Shock Absorber Inspection.................................................................................. 4-12

4.2.1.4.5 Fork Inspection.................................................................................................... 4-12

4.2.1.4.6 Nose Wheel Inspection........................................................................................ 4-12

4.2.1.5 Nose Gear Removal (Replacement)......................................................................... 4-13

4.2.1.5.1 Type of Maintenance........................................................................................... 4-13

Maintenance and Inspection Procedures Manual

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Series:

CTLS

LSA Page: v

AF 04800001 Revision No. 3 Date: 14 Sep 2008

4.2.1.5.2 Minimum Level of Certification ............................................................................ 4-13

4.2.1.5.3 Fork Removal ...................................................................................................... 4-13

4.2.1.5.4 Before Installation................................................................................................ 4-14

4.2.1.5.5 Fork Installation ................................................................................................... 4-14

4.2.1.5.6 Fork Replacement ............................................................................................... 4-15

4.2.1.5.7 Shock Absorber................................................................................................... 4-15

4.2.1.6 Nose Wheel...............................................................................................................4-16

4.2.1.6.1 Type of Maintenance........................................................................................... 4-16

4.2.1.6.2 Minimum Level of Certification ............................................................................ 4-16

4.2.1.6.3 Nose Wheel Removal and Installation ................................................................ 4-16

4.2.2 Main Landing Gear............................................................................................................ 4-18

4.2.2.1 Tools Required.......................................................................................................... 4-18

4.2.2.2 Materials Required.................................................................................................... 4-18

4.2.2.3 General ..................................................................................................................... 4-19

4.2.2.4 Inspection.................................................................................................................. 4-19

4.2.2.4.1 Type of Maintenance........................................................................................... 4-19

4.2.2.4.2 Minimum Level of Certification ............................................................................ 4-19

4.2.2.4.3 Visual inspection.................................................................................................. 4-19

4.2.2.4.4 Wheel Inspection................................................................................................. 4-19

4.2.2.5 Main Wheel Fairing Removal (Replacement)........................................................... 4-19

4.2.2.5.1 Type of Maintenance........................................................................................... 4-19

4.2.2.5.2 Minimum Level of Certification ............................................................................ 4-19

4.2.2.5.3 Procedure............................................................................................................ 4-20

4.2.2.6 Main Wheel Removal and Installation ...................................................................... 4-21

4.2.2.6.1 Type of Maintenance........................................................................................... 4-21

4.2.2.6.2 Minimum Level of Certification ............................................................................ 4-21

4.2.2.6.3 Wheel Brake Line Disconnecting ........................................................................ 4-21

4.2.2.6.4 Main Wheel Removal .......................................................................................... 4-21

4.2.2.6.5 Before Installation................................................................................................ 4-22

4.2.2.6.6 Main Wheel Installation ....................................................................................... 4-22

4.2.2.7 Removal (Replacement) of Main Strut Fairing.......................................................... 4-23

4.2.2.7.1 Type of Maintenance........................................................................................... 4-23

4.2.2.7.2 Minimum Level of Certification ............................................................................ 4-23

4.2.2.8 Main Gear Struts Removal and Installation.............................................................. 4-24

4.2.2.8.1 Type of Maintenance........................................................................................... 4-24

4.2.2.8.2 Minimum Level of Certification ............................................................................ 4-24

4.2.2.8.3 Procedure............................................................................................................ 4-24

4.2.2.9 Wheel Inspection and Maintenance.......................................................................... 4-25

4.2.2.9.1 Type of Maintenance........................................................................................... 4-25

4.2.2.9.2 Minimum Level of Certification ............................................................................ 4-25

4.2.2.9.3 Procedure............................................................................................................ 4-25

4.2.3 Brake System ....................................................................................................................4-27

4.2.3.1 Tools Required.......................................................................................................... 4-27

4.2.3.2 Materials Required.................................................................................................... 4-27

4.2.3.3 Inspection.................................................................................................................. 4-27

4.2.3.3.1 Type of Maintenance........................................................................................... 4-27

4.2.3.3.2 Minimum Level of Certification ............................................................................ 4-27

4.2.3.3.3 General................................................................................................................ 4-27

4.2.3.3.4 Inspection of Wheel Brakes................................................................................. 4-28

4.2.3.3.5 Inspection of Brake Controls ............................................................................... 4-29

4.2.3.4 Filling Brake System with Fluid................................................................................. 4-31

4.2.3.4.1 Type of Maintenance........................................................................................... 4-31

4.2.3.4.2 Minimum Level of Certification ............................................................................ 4-31

4.2.3.4.3 Procedure............................................................................................................ 4-31

4.2.3.5 Brake Pads Replacement......................................................................................... 4-32

4.2.3.5.1 Type of Maintenance........................................................................................... 4-32

4.2.3.5.2 Minimum Level of Certification ............................................................................ 4-32

4.2.3.5.3 Procedure............................................................................................................ 4-32

4.3 Flight Controls......................................................................................................................... 4-33

Maintenance and Inspection Procedures Manual

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Series:

CTLS

LSA Page: vi

AF 04800001 Revision No. 3 Date: 14 Sep 2008

4.3.1 Aileron................................................................................................................................ 4-33

4.3.1.1 New design of aileron control system....................................................................... 4-34

4.3.1.2 Tools Required.......................................................................................................... 4-35

4.3.1.3 Materials Required.................................................................................................... 4-35

4.3.1.4 General ..................................................................................................................... 4-35

4.3.1.5 Inspection.................................................................................................................. 4-35

4.3.1.5.1 Type of Maintenance........................................................................................... 4-35

4.3.1.5.2 Minimum Level of Certification ............................................................................ 4-35

4.3.1.5.3 Bracket Inspection............................................................................................... 4-36

4.3.1.5.4 Wing bracket bearings inspection ....................................................................... 4-36

4.3.1.5.5 Rods / Bellcranks inspection ............................................................................... 4-37

4.3.1.6 Aileron Installation..................................................................................................... 4-37

4.3.1.6.1 Type of Maintenance........................................................................................... 4-37

4.3.1.6.2 Minimum Level of Certification ............................................................................ 4-37

4.3.1.7 Aileron Adjustment.................................................................................................... 4-42

4.3.1.7.1 Type of Maintenance........................................................................................... 4-42

4.3.1.7.2 Minimum Level of Certification ............................................................................ 4-42

4.3.1.7.3 Rigging Aileron “Zero” Position............................................................................ 4-42

4.3.1.7.4 Aileron Deflection Adjustment ............................................................................. 4-44

4.3.1.7.5 Measuring Aileron Deflection............................................................................... 4-45

4.3.1.8 Verification of Aileron Installation and Adjustment ................................................... 4-47

4.3.2 Flaps.................................................................................................................................. 4-48

4.3.2.1 Tools Required.......................................................................................................... 4-48

4.3.2.2 Materials Required.................................................................................................... 4-48

4.3.2.3 General ..................................................................................................................... 4-49

4.3.2.4 Inspection.................................................................................................................. 4-49

4.3.2.4.1 Type of Maintenance........................................................................................... 4-49

4.3.2.4.2 Minimum Level of Certification ............................................................................ 4-49

4.3.2.4.3 Bracket Inspection............................................................................................... 4-49

4.3.2.4.4 Wing bracket bearings inspection ....................................................................... 4-50

4.3.2.4.5 Rods / Bellcranks inspection ............................................................................... 4-51

4.3.2.5 Flap Installation......................................................................................................... 4-51

4.3.2.5.1 Type of Maintenance........................................................................................... 4-51

4.3.2.5.2 Minimum Level of Certification ............................................................................ 4-51

4.3.2.5.3 Procedure............................................................................................................ 4-51

4.3.2.6 Flap Adjustment........................................................................................................ 4-53

4.3.2.6.1 Type of Maintenance........................................................................................... 4-53

4.3.2.6.2 Minimum Level of Certification ............................................................................ 4-53

4.3.2.6.3 Rigging “Zero” Position of the Flaps.................................................................... 4-53

4.3.2.6.4 Flap Deflection Adjustment.................................................................................. 4-54

4.3.2.6.5 Measuring Flap Deflection................................................................................... 4-56

4.3.2.7 Inspection of Flap Control Microswitches................................................................. 4-59

4.3.2.7.1 Type of Maintenance........................................................................................... 4-59

4.3.2.7.2 Minimum Level of Certification ............................................................................ 4-59

4.3.2.7.3 Procedure............................................................................................................ 4-59

4.3.3 Rudder............................................................................................................................... 4-60

4.3.3.1 Tools Required.......................................................................................................... 4-60

4.3.3.2 Materials Required.................................................................................................... 4-60

4.3.3.3 Rudder Installation and Removal.............................................................................. 4-60

4.3.3.3.1 Type of Maintenance........................................................................................... 4-60

4.3.3.3.2 Minimum Level of Certification Required............................................................. 4-60

4.3.3.3.3 Procedure............................................................................................................ 4-60

4.3.3.4 Rudder Deflection Adjustment.................................................................................. 4-63

4.3.3.4.1 Type of Maintenance........................................................................................... 4-63

4.3.3.4.2 Minimum Level of Certification ............................................................................ 4-63

4.3.3.4.3 Measuring Rudder Deflection.............................................................................. 4-64

4.3.3.4.4 Rigging Rudder Neutral Position......................................................................... 4-66

4.3.3.4.5 Adjusting of Control Cable Tension..................................................................... 4-67

4.3.3.4.6 Fine Adjustment................................................................................................... 4-68

Maintenance and Inspection Procedures Manual

Type:

Series:

CTLS

LSA Page: vii

AF 04800001 Revision No. 3 Date: 14 Sep 2008

4.3.3.4.7 Coarse Adjustment.............................................................................................. 4-68

4.3.3.5 Verification of Rudder Installation and Adjustment................................................... 4-69

4.3.4 Stabilator............................................................................................................................ 4-70

4.3.4.1 Tools Required.......................................................................................................... 4-71

4.3.4.2 Parts and Materials Required ................................................................................... 4-71

4.3.4.3 General ..................................................................................................................... 4-71

4.3.4.4 Stabilator Installation and Removal .......................................................................... 4-71

4.3.4.4.1 Type of Maintenance........................................................................................... 4-71

4.3.4.4.2 Minimum Level of Certification ............................................................................ 4-71

4.3.4.4.3 Procedure............................................................................................................ 4-71

4.3.4.5 Stabilator Adjustment................................................................................................ 4-77

4.3.4.5.1 Type of Maintenance........................................................................................... 4-77

4.3.4.5.2 Minimum Level of Certification ............................................................................ 4-77

4.3.4.5.3 Measuring Stabilator Deflection........................................................................... 4-78

4.3.4.5.4 Measuring of Trim Tab Deflection and Adjustment............................................. 4-81

4.3.4.6 Balancing of the Stabilator Balancer.........................................................................4-83

4.3.4.6.1 Type of Maintenance........................................................................................... 4-83

4.3.4.6.2 Minimum Level of Certification ............................................................................ 4-83

4.3.4.6.3 Procedure............................................................................................................ 4-83

4.3.4.7 Verification of Stabilator Installation and Adjustment ............................................... 4-84

4.4 Structural Repair..................................................................................................................... 4-85

4.4.1 Type of Maintenance......................................................................................................... 4-85

4.4.2 Minimum Level of Certification .......................................................................................... 4-85

4.4.3 Repair Procedures............................................................................................................. 4-85

4.5 Painting and Coating............................................................................................................... 4-85

4.5.1 Tools needed to accomplish the task................................................................................ 4-85

4.5.2 The parts needed to perform the task ............................................................................... 4-85

4.5.3 Type of Maintenance......................................................................................................... 4-85

4.5.4 Minimum Level of Certification .......................................................................................... 4-85

4.5.5 Puttying.............................................................................................................................. 4-85

4.5.6 Priming............................................................................................................................... 4-86

4.5.7 Painting.............................................................................................................................. 4-86

4.5.8 Polishing............................................................................................................................ 4-86

4.5.9 Method of Verification........................................................................................................ 4-86

5Engine.............................................................................................................................................. 5-1

5.1 Engine Systems and Accessories............................................................................................. 5-1

5.2 Rotax 912ULS Engine............................................................................................................... 5-1

5.3 Carb Heat Control..................................................................................................................... 5-2

5.3.1 Tools Required .................................................................................................................... 5-2

5.3.2 Materials Required............................................................................................................... 5-2

5.3.3 Type of Maintenance........................................................................................................... 5-2

5.3.4 Minimum Level of Certification ............................................................................................ 5-2

5.3.5 General................................................................................................................................ 5-2

5.3.6 Inspection of Carburetor Heater Control.............................................................................. 5-2

6Fuel System..................................................................................................................................... 6-1

6.1 General ..................................................................................................................................... 6-1

6.2 Tools Required.......................................................................................................................... 6-3

6.3 Materials Required.................................................................................................................... 6-3

6.4 General System Inspection.......................................................................................................6-3

6.4.1 Type of Maintenance........................................................................................................... 6-3

6.4.2 Minimum Level of Certification ............................................................................................ 6-3

6.4.3 Procedure............................................................................................................................ 6-3

6.5 Fuel Flow Check ....................................................................................................................... 6-4

6.5.1 Type of Maintenance........................................................................................................... 6-4

6.5.2 Minimum Level of Certification ............................................................................................ 6-4

6.5.3 Checking of Fuel Flow Rate ................................................................................................ 6-4

6.5.4 Simulation of In-Flight Engine Restart................................................................................. 6-4

6.6 Intake Filter / Side Access Panel .............................................................................................. 6-6

6.6.1 Type of Maintenance........................................................................................................... 6-6

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Series:

CTLS

LSA Page: viii

AF 04800001 Revision No. 3 Date: 14 Sep 2008

6.6.2 Minimum Level of Certification ............................................................................................ 6-6

6.6.3 Procedure............................................................................................................................ 6-6

6.7 Fuel Filter.................................................................................................................................. 6-8

6.7.1 Type of Maintenance........................................................................................................... 6-8

6.7.2 Minimum Level of Certification ............................................................................................ 6-8

6.7.3 Procedure............................................................................................................................ 6-8

6.8 Gascolator................................................................................................................................. 6-9

6.8.1 Type of Maintenance........................................................................................................... 6-9

6.8.2 Minimum Level of Certification ............................................................................................ 6-9

6.8.3 Procedure............................................................................................................................ 6-9

7Propeller .......................................................................................................................................... 7-1

7.1 Type of Maintenance................................................................................................................. 7-1

7.2 Minimum Level of Certification..................................................................................................7-1

7.3 Propeller Maintenance Procedures........................................................................................... 7-1

8Utility Systems................................................................................................................................. 8-1

8.1 Tools Required.......................................................................................................................... 8-1

8.2 Materials Required.................................................................................................................... 8-1

8.3 Cabin Heat System................................................................................................................... 8-1

8.3.1.1 Type of Maintenance .................................................................................................. 8-1

8.3.1.2 Minimum Level of Certification.................................................................................... 8-1

8.3.1.3 Procedure.................................................................................................................... 8-1

9Instruments and Avionics ................................................................................................................ 9-1

9.1 Tools Required.......................................................................................................................... 9-1

9.2 Parts Required.......................................................................................................................... 9-1

9.3 Instrument Maintenance............................................................................................................ 9-1

9.3.1 Type of Maintenance........................................................................................................... 9-1

9.3.2 Minimum Level of Certification ............................................................................................ 9-1

9.3.3 General................................................................................................................................ 9-1

9.3.4 Glass Cockpit Dynon EFIS 100........................................................................................... 9-1

9.3.5 Glass Cockpit Dynon EMS D120......................................................................................... 9-1

9.3.6 Analog Airspeed Indicator ................................................................................................... 9-2

9.3.7 Analog One Pointer Altimeter.............................................................................................. 9-2

9.3.8 Magnetic Compass with Deviation Table ............................................................................ 9-2

9.3.9 Flap position indicator.......................................................................................................... 9-2

9.3.10 Hobbs Hour Meter........................................................................................................... 9-2

9.3.11 Radio Garmin SL30 with VOR functionality .................................................................... 9-2

9.3.12 Radio Garmin SL40 installed with antenna..................................................................... 9-2

9.3.13 Transponder Garmin installation..................................................................................... 9-3

9.3.14 Altitude Encoder ACK A30 (Classic) or Dynon (Advanced)............................................ 9-3

9.3.15 GPS Garmin 496............................................................................................................. 9-3

9.3.16 ELT Ameriking AK450..................................................................................................... 9-3

9.3.17 Intercom PM 3000 A with aux music input and connection to GPS Audio ..................... 9-3

9.4 Inspection of Pitot & Static Port ................................................................................................ 9-4

9.4.1 Type of Maintenance........................................................................................................... 9-4

9.4.2 Minimum Level of Certification ............................................................................................ 9-4

9.4.3 Procedure............................................................................................................................ 9-4

9.5 Special Equipment.................................................................................................................... 9-5

10 Electrical System........................................................................................................................... 10-1

10.1 Tools Required........................................................................................................................ 10-1

10.2 Materials Required.................................................................................................................. 10-1

10.3 General ................................................................................................................................... 10-1

10.3.1 Inspection...................................................................................................................... 10-5

10.3.1.1 Type of Maintenance............................................................................................ 10-5

10.3.1.2 Minimum Level of Certification ............................................................................. 10-5

10.3.1.3 Procedure............................................................................................................. 10-5

10.4 Battery Replacement............................................................................................................... 10-5

10.4.1 Type of Maintenance..................................................................................................... 10-5

10.4.2 Minimum Level of Certification...................................................................................... 10-5

10.4.3 Procedure...................................................................................................................... 10-5

Maintenance and Inspection Procedures Manual

Type:

Series:

CTLS

LSA Page: ix

AF 04800001 Revision No. 4Date: 02 Jan 2009

Appendix I . Template for Trim Tab Deflection Angles Measurement ..........................................................1

Appendix II. Adjustment report......................................................................................................................1

Appendix III . Service Difficulty Report Form ................................................................................................1

Appendix IV . MATCO Brake System...........................................................................................................1

Maintenance and Inspection Procedures Manual

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Series:

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LSA Page: 1-1

AF 04800001 Revision No. 4Date: 02Jan 2009

1 General

This maintenance and inspection procedures manual provides all standard maintenance and inspection

procedures needed to keep the aircraft airworthy. This manual also states the certification requirements

for the persons performing each task. Maintenance tasks exceeding the scope of this manual are

possible but require prior coordination with and approval by the manufacturer.

The Flight Design CTLS is a three-axis control, high-wing, and two seats light sport aircraft of normal

scheme with a cruciform tail. The primary structures are made of carbon fiber reinforced plastic. The

aircraft is equipped with an all-moving stabilator with a trim tab and tricycle landing gear with a steerable

nose-wheel.

Federal rules require minimum certification levels of the mechanics perfoming individual maintenance

tasks on an S-LSA aircraft to be defined by the airframe manufacturer. Refer to chapter 2 for the definition

of the levels of certification applied throutghout this manual. On each individual task you will find the

allocation of level of certification.

WARNING: Use only alkali-free products when cleaning your composite aircraft. For

more information, refer to chapter 1.3 Care and cleaning of your CT.

1.1 Manufacturer

Flight Design GmbH

Sielminger Str. 51

D – 70771 L.-Echterdingen

Germany

1.2 Contact in USA

Flight Design USA

P.O. Box 325

South Woodstock, CT. 06267

860-963-7272

[email protected]

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