FLIGHT DESIGN CTLS Series Reference guide

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:
CT 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
2
1
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
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:
CT 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
8
(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
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
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
10-5 3
2
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
4
(cont.)
4-86 3
3-11 3 4-43 3 5-1 3
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
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
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
4-16 3
4
(cont.)
4-60 3
8
8-4 3

Maintenance and Inspection Procedures Manual
Type:
CT 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
Type:
CT 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
Type:
CT 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:
CT 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

Maintenance and Inspection Procedures Manual
Type:
CT 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:
CT 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
Type:
CT Series: CTLS 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]

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-2
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.3 Care and cleaning of your CT
Care must be taken when cleaning modern aircraft built with composite materials. Many products have
been developed to clean a specific type of material and may be unsuitable or even damaging to others.
Using the wrong product may damage your aircraft or its structures. Affected parts may be plainly visible
or may be hidden from view. The type of damage can vary from the simply unsightly to the outright
dangerous. You must always read the instructions for your cleaning products before using them. If you
should have any questions about a product’s suitability please contact your local dealer.
Each structure has its own cleaning requirements.
The basic airframe and wing structure
Composite aircraft are typically constructed of a sandwich of a structural material (Fiberglass-Carbon
Fiber or Kevlar) over a foam core.
The Flight Design CTLS is made up of a Carbon fiber-foam-Carbon fiber and Kevlar laminate sandwich
which is filled with polyester filler, sanded and painted with two-part urethane paint. The foam core of the
wings is partially Rohacell foam which was chosen for its stiffness and resistance to fuel. The fuselage
core is Airex foam which allows the contours for the CTLS fuselage.
The Rohacell foam, while highly resistant to fuel, is not resistant to strong Alkali cleaners or even water
with very high alkali content. Therefore Flight Design requires that the cleaners used on the CTLS be PH
neutral. Cleaners, such as Fantastik®, Formula 409®, Carbonex® and Castrol Super Clean®, which are
otherwise good Alkali cleaning products, should not be used on the CTLS.
The use of this category cleaner can dissolve the foam core of the sandwich leaving a dented looking
area that must be repaired and re-painted. Please note that the wing spars of the CTLS are sealed in
epoxy and fiberglass and cannot be damaged in this manner.
The windshield and side windows
The windows of the CTLS are tinted, heat molded acrylic (also known as Plexiglas®). While durable, they
must be carefully cleaned to avoid scratching the surface. Never use an abrasive pad, abrasive pastes or
even dirty rags when cleaning the window surfaces. Always flush the window surface with water to
remove as much dust and dirt before using an aircraft window specific cleaner or a plastic cleaner
approved for cleaning acrylic windshields.
When polishing the windshield or side windows never polish in a circular motion, this creates a halo affect
when looking into the sun. Always use horizontal or vertical pattern.
The engine and engine compartment
The Rotax 912 maintenance manual recommends the use of a commercially available cold cleaning
agent. Some citrus based products have been found to be suitable. However, always read the
instructions for any product to be used, keeping in mind that it must be compatible with both the engine
components and the airframe structures.

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-3
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.4 Views, dimensions

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-4
AF 04800001 Revision No. 3 Date: 14 Sep 2008
Geometry
Max. length 6604 mm 21 ft 8 in
Max. height 2342 mm 7 ft 8 in
Wing span 8594 mm 28 ft 2 in
Areas
Wing 9.98 m2107.43 sq ft
Stabilator 1.60 m217.20 sq ft
Vertical tail 1.41 m215.16 sq ft
Aspect ratios
Wing 7,29
Stabilator 3,38

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-5
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.5 Construction Materials
The airframe is made of high-quality composite materials which permit excellent aerodynamic
characteristics to be achieved at an efficient structural mass. Due to the strict mass regulations for ultra-
light aircraft, re-inforced carbon and aramide fiber materials predominate.
Due to the complex nature of composite materials and the necessary knowledge in the lay-up of a
specific structure, repair work on the composite airframe may only be undertaken by a qualified facility.
For this reason, only general information about the materials used is given in this handbook. Should the
aircraft structure be damaged, detailed information should be requested from the manufacturer.
Carbon, aramide, glass fiber: various qualities
Lange & Ritter, Gerlingen
Resin and hardener: Larit L 285
Lange & Ritter, Gerlingen
Core material: Rohacell, Airex various qualities
Lange & Ritter, Gerlingen
Screws and bolts: unless otherwise stated, class 8.8 zinc-plated or
stainless steel, according to DIN standard

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-6
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.6 Equipment List
Each aircraft is delivered with an initial equipment list as part of this handbook. A new equipment list must
be compiled and added to aircraft logbook and to this manual when there is any change to the equipment.
The owner of the aircraft is responsible for ensuring that the equipment list is current.
The equipment list includes options which are not certified in all the countries in which the CTLS may be
operated. It is the responsibility of the owner to ensure that national regulations are followed, for example
with respect to the ballistic recovery system and the autopilot.
The equipment list is a summary of the aircraft at the time of an annual inspection or weighing. It is
mandatory to record the installation and/or removal of instruments in the aircraft logbook.
.
Note: Sample weight and balance sheet only; not valid for the actual aircraft.

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-7
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.7 Source to Purchase Parts
Spare parts can be ordered from Flight Design USA (www.flightdesignusa.com ) along the Parts and
Assemblies Manual.
1.8 List of Disposable Replacement Parts
Air filter Air filter C2039, Art. C9997770
Fuel filter Fuel Filter 5/16’’, Art C9997813G
Oil filter Oil filter – according to Rotax maintenance manual
Front & Main wheel
Tyre 4.00-6 BfGoodrich 4PR PowerHoby
Tyre 4-ply 4.00 - 6" /4 PR V-5501 TT (B11)
Tyre 6PR Sava 4.00-6 6PR B11
Tube 3.50-6" not certified
Tube 4.00-6 Pn TR13
Tube Sava, 3.5.00-6 38G11.5, 6 ply
Tundra front wheel
Tube 4.00-6 Pn TR13
or
Tire 4.00-6 BfGoodrich 4PR PowerHoby
Tundra main wheel
Tyre 4-ply 6,00-6" Air TRAC (420x140)
or
Tyre 4-ply 6,00-6" Air TRAC
Batteries
Battery Powersafe SBS 8
or
Battery Cyclon
Master brake cylinder, Art C9997205L
O-Ring set for master brake cylinder
Brake pads for magnesium caliper, Art C9997214D
Aeroshell fluid 41 MIL-H-5606 Brake Fluid
Brake disk, Art C9997206M
Brake Assemblies
Caliper, Art C9997205K
Sparkplugs Ignition plug - according to Rotax maintenance manual

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-8
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.9 Weight and Balance Information
Maximum take off weight: 1320 lbs 600 kg
Typical empty weight: 683 lbs 310 kg
Typical useful load 622 lbs 290 kg
Maximum weight per seat: 260 lbs 118kg
Maximum baggage weight per side: 55 lbs 25 kg
Maximum fuel load (34 gal) 205 lbs 93 kg
The acceptable empty center of gravity range is 11.1 to 18.82 inches / 282-478 mm behind the leading
edge of wing.
Weighing:
The airplane is to be put on a level space on three scales or one scale with leveling blocks.
Make certain the plane is leveled using a bubble level put onto the tunnel between the seats.
The location of wheels is marked on the ground by a plumb.
The loaded center of gravity is located behind the leading edge of wing. Spanwise location of the datum is
not important, as the wings are rectangular and un-tapered.
Important:
While determining the loaded center of gravity the aircraft must be leveled.
A Weight and Balance Sheet supplied with each plane. The example of it is shown below.

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-9
AF 04800001 Revision No. 3 Date: 14 Sep 2008
Note: Sample weight and balance sheet only; not valid for the actual aircraft.

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-10
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.10 Tire Inflation Pressure
Main wheels: 29 PSI / 2 bar
Nose wheel: 29 PSI / 2 bar
1.11 Approved Fluids and Capacities
Quality automotive motor oil as specified by the engine manufacturer has to be used. The engine is not
approved for aircraft motor oil.
Allowed viscosities are listed in Chapter 10 of the Engine Operator’s Manual for all versions of ROTAX
912.
Do not use oil additives.
Oil capacity: 6,4 liq pt – min. 4,2 liq pt 3 l – min. 2 l
Oil consumption: max. 0.13 liq pt/h 0,06 l/h
The fuel valve is purely on / off and has to be in the appropriate maximum position. This engine does not
have a mixture valve or require leaning.
Fuel content: (2 wing fuel tanks for 65 l) 34 U.S. gal 130 l
Maximum fuel available: 33 U.S. gal 124 l
Fuel consumption: max 7 U.S. gal/h 27 l/h
Fuel specification: Premium Automotive Unleaded that conform to ASTM D 4814
Minimum AKI 91 for Rotax 912ULS or AVGAS 100 LL.
Cooling fluid: Cooling fluid in accordance with the Rotax Engine Operation Manual has to be
selected.
Attention: different coolants cannot be mixed! If in doubt, drain the complete
coolant content and replace completely with new coolant of one type.
Warning: Due to its high lead content AVGAS has a detrimental effect on valve seating and causes
greater deposition in the combustion chamber. It should thus only be used if fuel vapor or
octane problems arise or if MOGAS is not available.
Warning: When using AVGAS particular attention must be paid to type of oil used. For details refer
to the valid version of the ROTAX engine manual.
Warning: Engine relevant data given here is not complete. For complete information refer to the
current version of the relevant engine manual from the Rotax company.
Braking fluid: Aeroshell Fluid 41 MIL-H-5606 Brake Fluid

Maintenance and Inspection Procedures Manual
Type:
CT Series: CTLS LSA Page: 1-11
AF 04800001 Revision No. 3 Date: 14 Sep 2008
1.12 Recommended Fastener Torque Values and Bolts Installation
ATTENTION!
All bolts has to be mounted up to down, inside to outside or front to aft, unless explicitly stated
otherwise.
Bolt M5 DIN
912-8.8
Bolt M6 DIN
912-8.8
Bolt M8 DIN
912-8.8
Bolt M5 DIN
931 -8.8
Bolt M6 DIN
931 -8.8
Bolt M8 DIN
931 -8.8
Bolt
Bolt M5 DIN
933 – 8.8
Bolt M6 DIN
933 – 8.8
Bolt M8 DIN
933 – 8.8
Bolt M5
DIN
7991-8.8
(countersunk)
Bolt M6
DIN
7991-8.8
(countersunk)
Nut
Nut M5 DIN
985-8,8
Nut M6 DIN
985-8,8
Nut M8 DIN
985-8,8
Nut M5 DIN
985-8,8
Nut M6
DIN 985-
8,8
Recommended Torques
for class 8.8 (ISO 898)
fasteners
52 lb-in
5.9 N*m
89 lb-in
10 N*m
222 lb-in
25 N*m
52 lb-in
5.9 N*m
89 lb-in
10 N*m
For areas with thick
bonding seams (cotton +
cab-o-sil + resin +
hardener)
49 lb-in
5.5 N*m
80 lb-in
9 N*m
200 lb-in
22.5 N*m
40 lb-in
4.5 N*m
71 lb-in
8 N*m
Parts of PVC 49 lb-in
5.5 N*m
80 lb-in
9 N*m
200 lb-in
22.5 N*m
49 lb-in
5.5 N*m
80 lb-in
9 N*m
Carbon fabric composite
packages assemblies 49 lb-in
5.5 N*m
80 lb-in
9 N*m
200 lb-in
22.5 N*m
49 lb-in
5.5 N*m
80 lb-in
9 N*m
Plywood bonded into
composite 40 lb-in
4.5 N*m
71 lb-in
8 N*m
160 lb-in
18 N*m
31 lb-in
3.5 N*m
62 lb-in
7 N*m
Glass fiber composite
packages 49 lb-in
5.5 N*m
80 lb-in
9 N*m
200 lb-in
22.5 N*m
49 lb-in
5.5 N*m
80 lb-in
9 N*m
Metal parts assemblies
(steel, stainless steel,
aluminum alloys)
53 lb-in
6 N*m
89 lb-in
10 N*m
222 lb-in
25 N*m
53 lb-in
6 N*m
89 lb-in
10 N*m
As long as not stated otherwise within this manual, for bolts using standrad nuts, or botls otherwise
unsecured, Loctite must be applied. Middle strength loctite is to be used when bolts are mounted to
plastic components.
In all cases, used self locking nuts (with plastic locking ring) must be exchanged after new ones at any
time.