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FLIGHT DESIGN CT Airplane Maintenance Manual

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Airplane Maintenance Manual (AMM)
Airplane Type
Airplane Model
Airplane Registration Number : _______________
Airplane Serial Number
Document Number
Date of Issue
This document is approved under Manufacturer Self Declaration.
THIS DOCUMENT IS THE PROPERTY OF FLIGHT DESIGN general aviation GmbH
AND MAY NOT BE CITED, REPRODUCED, DISCLOSED OR DISTRIBUTED IN WHOLE OR IN PART
WITHOUT PRIOR EXPRESS WRITTEN PERMISSION OF FLIGHT DESIGN general aviation GmbH
Template No.: PZ 0100 0034_02
:
CT
:
CTLS-LSA
F-09-02-12
: _______________
: AF 0480 0015
: 15-Jul-15

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Summary of Contents for FLIGHT DESIGN CT

  • Page 1 : 15-Jul-15 This document is approved under Manufacturer Self Declaration. THIS DOCUMENT IS THE PROPERTY OF FLIGHT DESIGN general aviation GmbH AND MAY NOT BE CITED, REPRODUCED, DISCLOSED OR DISTRIBUTED IN WHOLE OR IN PART WITHOUT PRIOR EXPRESS WRITTEN PERMISSION OF FLIGHT DESIGN general aviation GmbH...
  • Page 2 RECORD OF MANUAL REVISIONS Manual revisions are provided by Flight Design GmbH as available and approved through the Agency (if applicable). The updates shall be manually entered to the individual printed version of the AMM by the owner/operator of the aircraft.
  • Page 3 Rev. Sections Sections Rev. Sections Sections Date Signature Date Signature Removed Inserted Removed Inserted Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 4 LIST OF EFFECTIVE SECTIONS Section Rev. Section Rev. Approval Reference Approval Reference Manufacturer Self Declaration 55-30 Manufacturer Self Declaration Manufacturer Self Declaration 55-40 Manufacturer Self Declaration Manufacturer Self Declaration 56-00 Manufacturer Self Declaration 01-00 Manufacturer Self Declaration 57-00 Manufacturer Self Declaration 02-00 Manufacturer Self Declaration 57-00...
  • Page 5 TABLE OF CONTENTS GENERAL CHAPTER 01 – INTRODUCTION CHAPTER 02 – ORGANIZATION AND HANDLING OF THE MANUAL CHAPTER 03 – GENERAL DESCRIPTION OF THE AIRPLANE CHAPTER 04 – AIRWORTHINESS LIMITATIONS AIRCRAFT CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK SECTION 05-10 – TIME LIMITS SECTION 05-20 –...
  • Page 6 STRUCTURES CHAPTER 51 – STANDARD PRACTICES AND STRUCTURES SECTION 51-10 – INVESTIGATION SECTION 51-20 – REPAIR PROCESSES SECTION 51-30 – MATERIALS SECTION 51-70 – REPAIRS CHAPTER 52 – DOORS SECTION 52-30 – BAGGAGE DOORS CHAPTER 53 – FUSELAGE CHAPTER 55 – STABILIZERS SECTION 55-10 –...
  • Page 7 Operating and Maintenance Manual of the installed propeller Other equipment manufacturer instruction made applicable with this AMM, refer to Appendix I. 01-00.2 Approval The contents of this document is approved by Flight Design under manufacturer self declaration. Document Title Document No.
  • Page 8 Recovery of Certification You may contact Flight Design either directly, or through the Flight Design distributor or service center that is responsible for your area. You can find contact details of the distributors and service centers on the Flight Design web page.
  • Page 9 Flight Design distributor or service center that is responsible for your area. You can find contact details of the distributors and service centers on the Flight Design web page. 01-00.8 List of Disposable Replacement Parts Air filter RU0810 RD CNT AIR FILTER;...
  • Page 10 CHAPTER 02 – ORGANIZATION AND HANDLING OF THE MANUAL Contents 02-00.1 Manual Structure 02-00.1.1 Chapter and Subchapter Structure 02-00.1.2 Page Numbering System 02-00.1.3 Figures 02-00.1.4 Warnings, Cautions and Notes 02-00.1.5 Abbreviations 02-00.2 Manual Handling 02-00.2.1 Record of Revisions 02-00.2.2 List of Effective Sections 02-00.2.3 Feedback Template 02-00.1 Manual Structure...
  • Page 11 02-00.1.5 Abbreviations The table below contains the abbreviations used in this AMM. Abbreviation Meaning Airplane Maintenance Manual Air Traffic Control Civil Aviation Authority – used to refer to the Authority of any applicable country Calibrated Airspeed (indicated airspeed, corrected for installation and instrument errors. CAS is TAS at ISA standard atmosphere at MSL) Center of Gravity EASA...
  • Page 12 SDR number:_______ Service Difficulty Report (SDR) (to be filled by Flight Design) Flight Design general aviation Use this template only for difficulties experienced during maintenance GmbH or servicing. Am Flugplatz 3 Describe the difficulties experienced with the aircraft; state the occasion, D-99820, Hörselberg Hainich...
  • Page 13 CHAPTER 03 – GENERAL DESCRIPTION OF THE AIRPLANE Contents 03-00.1 General 03-00.2 Equipment List 03-00.1 General The CTLS-LSA is a two seat aircraft of composite construction. The aircraft is arranged as a high wing mono-plane with cantilevered wings and a conventional empennage. The aircraft incorporates a tricycle landing gear.
  • Page 14 ● Note: This is only the sample of the equipment list; not valid for the actual aircraft. Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 03-00-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 15 CHAPTER 04 – AIRWORTHINESS LIMITATIONS Contents 04-00.1 General 04-00.2 Airworthiness Limitations 04-00.2.1 Airframe 04-00.2.2 Outside Painting and Temperature Limit 04-00.2.3 Structural Repairs 04-00.3 Continued Airworthiness 04-00.4 Life Limited Components 04-00.1 General This chapter gives information on mandatory limitations established by the airframe manufacturer.
  • Page 16 The aircraft is not equipped with life limited components. Time limits as listed in CHAPTER 05 shall be used to ensure continued airworthiness of the Flight Design CTLS-LSA, unless an alternate inspection program is approved by the competent National Airworthiness Authority.
  • Page 17 CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK Contents 05-00.1 General 05-00.2 Levels of Certification SECTION 05-10 – TIME LIMITS 05-10.1 General 05-10.2 Scheduled Maintenance Time Limits 05-10.3 Component Time Limits SECTION 05-20 – SCHEDULED MAINTENANCE CHECK 05-20.1 General 05-20.2 Scheduled Maintenance Checklist CTLS-LSA 05-20.2.1 Identification...
  • Page 18 05-00.2 Levels of Certification Levels of certification used in this manual are: Pilot/Owner Pilot or owner of the aircraft. Depending form national requirements, (P/O): the pilot or owner must show specific qualification. Examples are qualification requirements in accordance with Part- M.A.803, applicable for EASA countries.
  • Page 19 SECTION 05-10 – TIME LIMITS 05-10.1 General All scheduled maintenance checks have time limits. You shall do the scheduled maintenance within the time limits. 05-10.2 Scheduled Maintenance Time Limits The table below contains scheduled maintenance time limits recommended by the manufacturer.
  • Page 20 Chapter Item Overhaul Replacement 25-00.2.2 Safety Harness pilot/ Co-pilot 12 years 32-20 Shock absorber elements in the nose gear 5 years 32-40 Flexible hoses of the aircraft brake system 10 years 25-62 ELT Battery 26-00 Fire Extinguisher Structure – a comprehensive airframe Inspection at 6.000 h 05-20.4 inspection is mandatory when reaching the...
  • Page 21 SECTION 05-20 – SCHEDULED MAINTENANCE CHECK 05-20.1 General Perform the scheduled maintenance checks in this Section at the intervals (flight hours and calendar time) marked in SECTION 05-20 with a “ ” or at the time specified. ● Note: Only persons authorized by the National Aviation Authority of the country where the airplane is registered may perform these checks.
  • Page 22 05-20.2.2 Aircraft Records Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Aircraft records. Check the presence and condition of the Registration certificate and the Airworthiness Certificate. Aircraft identification tag. Check that the tag is secure and readable. Aircraft, Engine and Propeller logbooks.
  • Page 23 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Engine and engine compartment Clean for leakage check Run up of engine: Conduct per following checklist, fill pre-inspection values only: Systems Pre-inspection Post-inspection Engine oil. Check the level of oil and follow the Operator’s ®...
  • Page 24 05-20.2.4 Post Run-Up, Pre-inspection and Preparations Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Airframe, engine, propeller Perform a walk around to detect damages, fluid leaks or other abnormalities, Check visual the installation geometry between fuselage/ wing/ empennage and engine/ propeller/ cowling Check leveling of aircraft on ground.
  • Page 25 05-20.2.5 Propulsion System Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Cleaning. Clean the engine as required in the ® Maintenance Manual for ROTAX Engine Type 912 Series. Spinner. Remove the spinner. Inspect for cracks, security to propeller. Clean the spinner inside. Refer to Section 61.3.1 Spinner plate.
  • Page 26 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Coolant hoses and lines. Check for damage, leakage, hardening from heat, porosity, for loose connections and secure attachments. Check routing for kinks and restricted elbows. Check fire protection shielding. Refer to CHAPTER 75 Oil Lines.
  • Page 27 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Air filter box. Check that the sealing surfaces are in good condition and clean. Inspect and clean filter. Replace if necessary. Clean air filter box inside. Check the drain hole at the bottom of the box for obstructions or blockage.
  • Page 28 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Engine mount. Check mounting bolts for condition and correct values. At engine (4 bolts M10): 35 Nm At shock mounts (4 bolts M10): 35 Nm 200h LSAM At firewall (6 bolts M8): 22.5 Nm Replace safety wire where necessary Refer to Section 71-00.3.2...
  • Page 29 05-20.2.6 Fuselage Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Skin surface. Inspect for obvious signs of damage, including cracks, holes, buckling. Check the drain LSAM holes for obstructions. Check the paint condition and cleanliness. Main frame. Inspect for cracks, dents, and delamination from the fuselage.
  • Page 30 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Wing attachment area. Remove the wings Refer to Section 57-00.3.1 Check the fuselage root ribs for cracks and delaminations. Check the tunnel for wing tongues for any signs of damages. 600h Inspect the bushes/ ball eyes for wing pin or 2...
  • Page 31 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Rudder control cables. Inspect control cables, control cable guides, cable connections, turnbuckles, and hardware for correct installation, LSAM wear, securing and proper operation. Check cable tension. Refer to Section 27-20.3.4 Flap actuator.
  • Page 32 05-20.2.7 Wings Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Wings, Ailerons, Flaps. Check condition of paint and inspect for obvious signs of damage, including cracks, dents, holes, buckling and other evidence LSAM of failure. Take special care for leading and trailing edge area.
  • Page 33 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Wing interior. Inspect the wing spar through the outer access panel and access holes along the trailing edge for signs of cracks or delaminations. 200h LSAM Inspect visible bonded areas of ribs and other structures.
  • Page 34 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Fuel tanks. Check the wing leading edge for cracks and for fuel leaks. Inspect the outer skin in the fuel tank area for fuel leaks. Inspect the visible LSAM area of the fuel tank for foreign objects.
  • Page 35 05-20.2.8 Empennage Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Empennage. Inspect complete surface of the vertical and horizontal Stabilator, of the trim tab, of LSAM the rudder and underfin for damage such as dents, cracks, holes and delaminations. Underfin.
  • Page 36 05-20.2.9 Landing Gear Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Wheel fairings and upper main landing gear fairings. Inspect for condition, scratches, cracks, and signs of overstress. Clean the fairings inside. Fairing mounts. Inspect for cracks, distortion or other damages.
  • Page 37 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Shock absorber. Inspect the shock absorber of nose landing gear for binding and unusual noises LSAM while operating. Refer to Section 32-20.3.6 Brake System. Clean and check hydraulic cylinders, activation handle and connections for condition, braking fluid leaks, for cracks and corrosion, security of components.
  • Page 38 05-20.2.10 Cabin and Baggage Compartment Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Fire extinguisher. Remove the fire extinguisher (if applicable) and check that expiration date is not exceeded. Replace if necessary. Refer to CHAPTER 26 Safety belts.
  • Page 39 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification ELT. Dismount the ELT from the bracket and remove the battery cover. Inspect for battery corrosion and any obvious internal or external damage to housing. Check that the battery replacement date matches the date on the housing placard.
  • Page 40 Minimum Inspection and/or Required Maintenance Initials / Level of Checklist Remarks Certification Engine. Run the engine for no more than two minutes at 1400 to 1800 RPM. After shutdown, check for the oil filter leaks, and any other components removed during this inspection. Install the cowlings, if there are no leaks detected.
  • Page 41 LSA reaching the defined time limit. When you are approaching the time limit and no inspection program is published, contact Flight Design in due time before reaching the time limit, so that the inspection program can be announced. Document Title Document No.
  • Page 42 SECTION 05-30 – UNSCHEDULED MAINTENANCE CHECK Please contact the aircraft manufacturer for further instructions. Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 05-30-1 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 43 CHAPTER 06 – DIMENSIONS Contents 06-00.1 General 06-00.2 Dimensions 06-00.3 Three-View Drawing 06-00.1 General In this chapter you can find the information on the airplane main dimensions and the three- view drawing of the CTLS-LSA. All dimensions shown below are approximate. 06-00.2 Dimensions General Max.
  • Page 44 06-00.3 Three-View Drawing Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 06-00-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 45 CHAPTER 07 – JACKING Contents 07-00.1 General 07-00.2 Jacking 07-00.1 General This chapter provides instructions for jacking of the aircraft. ▲Warning: Take particular care when jacking the complete aircraft. The fuselage is a delicate, light-weight composite sandwich structure. Distribute jacking load over large area and stop aircraft from rolling to the side.
  • Page 46 CHAPTER 08 – WEIGHING AND LEVELING Contents 08-00.1 General 08-00.2 Weighing and Leveling 08-00.1 General This chapter provides you with information how to weight and level an airplane. 08-00.2 Weighing and Leveling 08-00.2.1.1 Type of Maintenance Line 08-00.2.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 08-00.2.1.3 Procedure A.
  • Page 47 CHAPTER 09 – TOWING AND TAXIING Contents 09-00.1 General 09-00.2 Description 09-00.3 Placards and Markings 09-00.4 Maintenance Practices 09-00.4.1 Towing 09-00.4.2 Markings Installation 09-00.1 General This chapter provides you with information how to weight and level an airplane. 09-00.2 Description The aircraft is equipped with an interface for Tow Bar connection, there are two protruded pins attached to the nose gear leg.
  • Page 48 09-00.3 Placards and Markings The tow bar may only be used when the following markings are present on the aircraft (Fig. 09-00-2). Markings must match with the rudder control system stop adjustment. Fig. 09-00-2 Two red lines on the cowling mark the maximum deflection obtainable with the nose gear. One red line on the nose wheel fairing marks the center reference line of the nose wheel and provides the steering position.
  • Page 49 09-00.4 Maintenance Practices 09-00.4.1 Towing 09-00.4.1.1 Type of Maintenance Line 09-00.4.1.2 Minimum Level of Certification Pilot/Owner (P/O) 09-00.4.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Towing bar B. Towing Step Action Reference To attach the towing bar to the towing pins, follow the instructions of the individual towing bar design.
  • Page 50 09-00.4.2 Markings Installation 09-00.4.2.1 Type of Maintenance Line 09-00.4.2.2 Minimum Level of Certification Pilot/Owner (P/O) 09-00.4.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Markings Installation When cowling and/or nose wheel fairing has been replaced, or when the markings do not match with the actual adjustment of the rudder control system stops, or when the existing markings are damaged and unusable, new markings must be applied as follows.
  • Page 51 Fig. 09-00-7 Fig. 09-00-8 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 09-00-5 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 52 CHAPTER 11 – PLACARDS AND MARKINGS Contents 11-00.1 General 11-00.2 Placards and Markings 11-00.1 General This chapter provides you with information about exterior and interior placards and markings. 11-00.2 Placards and Markings The aircraft is equipped with the following markings and placards: Item Location Warning labels –...
  • Page 53 Both sides of the baggage Baggage payload compartment Baggage payload Both sides of the hat rack Both sides of the baggage Warning compartment These placards markings are required minimum and are listed in the POH in Section 2 – Limitations. The following additional placards are applied: Engine operation Adjacent to the relevant control...
  • Page 54 CHAPTER 12 – SERVICING Contents 12-00.1 General SECTION 12-10 – REPLENISHING 12-10.1 General 12-10.2 Replenishing Practices 12-10.2.1 Refueling and Defueling 12-10.2.2 Fuel Contamination Test 12-10.2.3 Fuel Flow Rate Check 12-10.2.4 Replenishing of Engine Oil 12-10.2.5 Oil Changing 12-10.2.6 Replenishing of Coolant 12-10.2.7 Coolant Changing 12-10.2.8...
  • Page 55 SECTION 12-10 – REPLENISHING 12-10.1 General This section provides instructions concerning replenishing procedures. 12-10.2 Replenishing Practices 12-10.2.1 Refueling and Defueling Fuel content: 130 l (65 l per wing tank) Maximum Usable fuel: 124 l Fuel specification: EN 228 Super min. RON 95 EN 228 Super plus min.
  • Page 56 12-10.2.2 Fuel Contamination Test 12-10.2.2.1 Type of Maintenance Line 12-10.2.2.2 Minimum Level of Certification Pilot/Owner (P/O) 12-10.2.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Transparent fuel tester B. Fuel Contamination Test Do this test each day you operate the airplane. Step Action Reference...
  • Page 57 B. Fuel Flow Rate Check Check the fuel flow per minute of each tank through the gascolator exactly and note and compare with the previous fuel flow rate. If there is a drop more than 5%, then check full system (bows in fuel lines) and if still a difference, check the fuel filters in the wings. Step Action Reference...
  • Page 58 12-10.2.4.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Replenishing of Engine Oil Step Action Reference Open the inspection hatch in the top cowling. Remove the small filler cap. Get the dip stick from the oil tank. Clean the oil dip stick.
  • Page 59 ▲Warning: Engine operation with no coolant (or very low coolant level) will cause engine malfunction or failure. ▲Warning: Waterless coolant is not permitted on Flight Design LSA aircraft. 12-10.2.7.1 Type of Maintenance Line 12-10.2.7.2 Minimum Level of Certification LSA- Mechanic (LSAM) Document Title Document No.
  • Page 60 12-10.2.7.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Coolant Changing Step Action Reference ® Prepare coolant mixture in accordance with ROTAX Operation Manual Remove the cowlings 71-00.3.1 Disconnect the system in any lowest point Drain the coolant to any suitable container Connect disconnected hoses.
  • Page 61 activated. Screw in the connector A (Fig. 12-10.1). Close the valve and move the handle 2 to 3 times back and forth. Note if there are air bubbles in the line nearby the check valve. Inspect joints and connections for leaks. Open the valve sharply (Fig.
  • Page 62 12-10.2.9 Tire Inflation Main wheels: 29 PSI / 2 bar Nose wheel: 29 PSI / 2 bar 12-10.2.9.1 Type of Maintenance Line 12-10.2.9.2 Minimum Level of Certification Pilot/Owner (P/O) 12-10.2.9.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B.
  • Page 63 SECTION 12-20 – SCHEDULED SERVICING 12-20.1 General This section provides lubrication schedule and list of recommended lubricants. 12-20.2 Lubrication Chart Item Interval, hours Recommended Lubricant Supplier Retinax EP2, SHELL Hinges of cabin doors Alvania EP2 Retinax EP2, SHELL Sliding supports of rudder 1000 pedals Alvania EP2...
  • Page 64 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-LSA 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.
  • Page 65 12-30.4 Cleaning of 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.
  • Page 66 CHAPTER 20 – STANDARD PRACTICES ON AIRFRAME Contents 20-00.1 General 20-00.2 Bolt and Nut Types Used in the Airplane 20-00.3 Recommended Torque Values 20-00.4 Standard Practices on Airframe 20-00.4.1 Installation of the Safety Wire 20-00.4.2 Adjustment of Control Rods Length 20-00.4.3 Crimping of Rudder Cables 20-00.4.4...
  • Page 67 Bolt M5 DIN Bolt M6 DIN Bolt M8 DIN 912-8.8 912-8.8 912-8.8 Bolt M5 DIN Bolt M6 DIN Bolt M5 DIN Bolt M6 DIN Bolt M8 DIN Bolt 7991-8.8 7991-8.8 931-8.8 931-8.8 931-8.8 (countersunk) (countersunk) Bolt M5 DIN Bolt M6 DIN Bolt M8 DIN 933-8.8 933-8.8...
  • Page 68 20-00.4 Standard Practices on Airframe 20-00.4.1 Installation of the Safety Wire 20-00.4.1.1 Type of Maintenance Line 20-00.4.1.2 Minimum Level of Certification Pilot/Owner (P/O) 20-00.4.1.3 Procedure Safety wire is used on cylinder studs, control cables turnbuckles and engine accessory attaching bolts. There are two methods of safety wiring: the double-twist method that is most commonly used, and the single-wire method used on screws, bolts, and/or nuts in a closely-spaced or closed-geometrical pattern such as a triangle, square, rectangle, or circle.
  • Page 69 A. Recommended Special Tools and Parts Item Quantity Unit Wire twisting tool B. Wiring the bolts (Fig. 20-00-2) Step Action Reference Thread the safety wire through the hole provided in bolt head. When the bolts are closely grouped – it is more convenient to wire them in series. Rote the safety wire in a manner that will prevent the tendency of the part to loosen.
  • Page 70 20-00.4.2 Adjustment of Control Rods Length 20-00.4.2.1 Type of Maintenance Line 20-00.4.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 20-00.4.2.3 Procedure Each controls push rod is provided with adjustable rod ends. ▲Warning: When the length of rod has been adjusted, the rod end must be properly locked by the lock-nut.
  • Page 71 20-00.4.3 Crimping of Rudder Cables 20-00.4.3.1 Type of Maintenance Line 20-00.4.3.2 Minimum Level of Certification LSA- Mechanic (LSAM) 20-00.4.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Nicopress tool B. Crimping of Rudder Cables (Fig. 20-00-5) Step Action Reference Thread the cable end through the sleeve in a manner to create a loop Install the thimble to the loop.
  • Page 72 20-00.4.4 Usage of Bonding Liquids 20-00.4.4.1 Type of Maintenance Line 20-00.4.4.2 Minimum Level of Certification Pilot/Owner (P/O) 20-00.4.4.3 Procedure Middle strength bonding liquid (Loctite 243) is applied to the screws where no other means of protection against the loosening (self-locking nuts, safety wire) are not provided. A.
  • Page 73 Step Action Reference Prepare hose and fire sleeve required length. Fire sleeve must be 20÷25mm/1`` longer than hose. Put the fire sleeve to hose. Put the band clamp to fire sleeve. Push fire sleeve back from end of hose. Cover not less 25mm/1`` of fire sleeve with the fireproof silicone and allow to dry. Put the band clamp to end of hose.
  • Page 74 CHAPTER 21 – AIR CONDITIONING Contents 21-00.1 General 21-00.2 Description 21-00.2.1 Cabin Ventilation 21-00.2.2 Cabin Heat 21-00.3 Maintenance Practices 21-00.3.1 Cabin Heating System Inspection 21-00.3.2 Inspection and Repair in Case of Malfunction 21-00.1 General This chapter provides description of the cabin ventilation and cabin heat. 21-00.2 Description 21-00.2.1 Cabin Ventilation...
  • Page 75 Fig. 21-00-2 Fig. Item Part Name Torque Reference Shroud KF21400100 Thermic Choke KF21400200 Air Terminal Unit KF21400400 KF21400005 21-00-1 Washer KF21400006 21-00-2 Vent KF21400040 Aeroduct Hose C9993188 Clamp C9997723 Screw C9996159C Clamp, Shroud C9997710A, C9997726 A cabin heat valve allows to regulate the amount of warm air that is guided into the cabin. Within the cabin the warm air is distributed between two openings (one per side) at the side of the main tunnel, next to the pilot and copilot feet, and to slots in the upper instrument console, right at the lower rim of the windscreen.
  • Page 76 21-00.3 Maintenance Practices 21-00.3.1 Cabin Heating System Inspection 21-00.3.1.1 Type of Maintenance Line 21-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 21-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Cabin Heating System Inspection Step Action Reference Remove the cowlings to get access to the lower part of the firewall.
  • Page 77 B. Inspection and Repair in Case of Malfunction B1. If the cabin heater choke does not operate, inspect the connecting cable between the choke and the handle and eliminate damage as follows: Step Action Reference Check if there is the spring С9997703В Spring 0.5x5.0x25.0 at the Cabin Heater Choke KА7040200.
  • Page 78 secure it with the sleeve С9997056Е (Nicopress stop sleeve 1.5-1.7 mm). If frayed, replace the cable to a new one С9997065В (Steel rope 7x7 1 mm), 59 in. / 1.5 m long. While replacing the handle must be pushed in. (Fig.
  • Page 79 С9993188 (AERODUCT tube CEET-7 1-3/4 ID) in the cabin as follows: Unscrew the bolt by a cross-screwdriver or wrench with header 7 and release the clamp С9997723 Clamp 40-60 that secures the hose С9993188 (AERODUCT tube CEET-7 1-3/4 ID) near KВ7040400 Air branch canal. (Fig.
  • Page 80 Fig. 21-00-8 Replace the damaged piece of hose С9993188 (AERODUCT tube CEET-7 1-3/4 ID) to a new one of the same length. Put the clamps С9997723 (Clamp 40-60) on the new hose С9993188 (AERODUCT tube CEET-7 1-3/4 ID). Tighten the clamps С9997723 (Clamp 40-60) by a cross-screwdriver or wrench with header 7.
  • Page 81 Fig. 21-00-10 Release the nuts С9997499В (Soldering nut M8x1) by a screwdriver with header 12 (unscrew 3-5 turns towards the engine, but do not remove them). Remove the muffler KА5020500 (Muffler with exhaust pipe). (Fig. 21-00-10). Unscrew the bolt by a cross-screwdriver or wrench with header 7 and release the clamp С9997723 Clamp 40-60 that secures the hose С9993188 (AERODUCT tube CEET-7 1-3/4 ID) near the heater KU7040120 (Air heater) in the engine compartment.
  • Page 82 with header 7 To change a damaged hose С9993188 (AERODUCT tube CEET-7 1-3/4 ID) between the Cabin heater choke KА7040200 and KВ7040400 (Air branch canal) do the following. Set the control handle to OFF position. (Fig. 21-00-3). Unscrew the lower bolts of the instrument board KА1081000 by a 3 hex-nut screwdriver.
  • Page 83 CHAPTER 23 – INSTRUMENTS Contents 23-00.1 General 23-00.2 Description SECTION 23-10 – SPEECH COMMUNICATION 23-10.1 General 23-10.2 Description 23-10.3 Maintenance Practices 23-10.3.1 Radio Installation, Removal and Maintenance 23-10.3.1 COM Antenna Uninstalling and Installing 23-10.3.2 COM Antenna Inspection 23-00.1 General This chapter provides description Instruments. The aircraft is provided with minimum equipment.
  • Page 84 Fig. 23-00-1. Upper Panel with basic analog cockpit, basic ATC equipment Pos. Manufacturer Type Description Winter 6 FMS 4 Analog airspeed indicator 3.25 in, km/h or kt Winter 4 FGH 10 Analog three pointer altimeter, 80 mm Winter Gr 1 Slip indicator, 58 mm Winter 5 STVM 5...
  • Page 85 Aux music input. To fast mute music, switch to the channel that has no active input Aux music input (MP3 player or similar) Flight Design Flap position selector display. Flashes when selected position not yet reached; shows flap position permanent...
  • Page 86 SECTION 23-10 – SPEECH COMMUNICATION 23-10.1 General This section provides description and information about Speech Communication System. 23-10.2 Description The speech communication system represents the radio Garmin SL40 is typically installed to the upper center panel. Every installation of a radio goes along with an intercom that is typically installed to the lower center panel.
  • Page 87 23-10.3.2 COM Antenna Uninstalling and Installing 23-10.3.2.1 Type of Maintenance Line 23-10.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 23-10.3.2.3 Procedure COM Antenna Comant CI-121(optionally RAMI AV-10) assembly is shown on Fig. 23-10-1. A. Recommended Special Tools and Parts Item Quantity Unit None...
  • Page 88 23-10.3.3 COM Antenna Inspection 23-10.3.3.1 Type of Maintenance Line 23-10.3.3.2 Minimum Level of Certification Pilot/Owner (P/O) 23-10.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Antenna Inspection Step Action Reference Check security of attachment Check communication Document Title Document No.
  • Page 89 CHAPTER 24 – ELECTRICAL SYSTEM Contents 24-00.1 General 24-00.2 Description 24-00.3 Maintenance Practices 24-00.3.1 Starter Relay Uninstalling and Installing 24-00.3.2 Capacitor Uninstalling and Installing 24-00.3.3 Battery Uninstalling and Installing 24-00.3.4 Circuit Breakers Uninstalling and Installing 24-00.3.5 Switches Uninstalling and Installing 24-00.3.6 Electrical Wiring System Inspection 24-00.3.7...
  • Page 90 Fig. 24-00-1. Electrical System - Simplified Block Diagram Fig. 24-00-2 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 24-00-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 91 24-00.3 Maintenance Practices 24-00.3.1 Starter Relay Uninstalling and Installing 24-00.3.1.1 Type of Maintenance Line 24-00.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 24-00.3.1.3 Procedure Starter Relay assembly is shown on Fig. 24-00-3. A. Recommended Special Tools and Parts Item Quantity Unit None B.
  • Page 92 Fig. Item Part Name Torque Reference Starter relay assy C9997494 Cap for nut M6 C9996364 Self-locking nut DIN 985-M6, regular C9996334 Washer DIN 125 A2B-6.4mm C9996504 24-3 Self-locking nut DIN 985-M5, regular C9996333 Washer DIN 9021-5.3mm VZ C9996563 Washer DIN 9021-5.3mm VZ C9996563 Bolt DIN 933-M5x16-8.8 C9996283...
  • Page 93 Fig. Item Part Name Torque Reference Socket double flat 6.3х0.8mm 1.5-2.5sqmm C9997129G Socket flat iso. blue 6.3х0.8mm 1.5-2.5sqmm C9997128H 24-4 Capacitor Type LG 22000mkF 25V C9999355P SEPCO Fire Sleeve RL2274G-5/8" C9993189G TY-wraps CV-250 white C9997727F 24-00.3.3 Battery Uninstalling and Installing 24-00.3.3.1 Type of Maintenance Line 24-00.3.3.2 Minimum Level of Certification...
  • Page 94 Fig. 24-00-5 Fig. Item Part Name Torque Reference Battery SBS 8 C9997180C Bracket Battery KF24000053 Bolt DIN 933-M5x16-8.8 C9996283 Washer DIN 9021-5.3mm VZ C9996563 24-5 Self-locking nut DIN 985-M5, regular C9996333 Cap for Battery C9997180D Washer DIN 125 A2B-6.4mm C9996504 Bolt part of set C9997180C 24-00.3.4...
  • Page 95 Step Action Reference Switch off power: turn off all instruments; pull out master breakers (BAT and 31.3.1.3 GEN) on the panel lower section Unscrew circuit breaker attachment nut Remove the circuit breaker Remove shrink hose Unscrew attachment bolts M4 that hold the sockets to circuit breaker terminals С.
  • Page 96 B. Circuit Breakers Uninstalling Step Action Reference Switch off power: turn off all instruments; pull out master breakers (BAT and 31.3.1.3 GEN) on the panel lower section By the pressing switch locks remove switch Remove shrink hose Disconnect socket connectors С.
  • Page 97 24-00.3.7 Starter Inspection 24-00.3.7.1 Type of Maintenance Line 24-00.3.7.2 Minimum Level of Certification Pilot/Owner (P/O) 24-00.3.7.3 Procedure To inspect the starter connections refer to Fig. 24-00-8. A. Recommended Special Tools and Parts Item Quantity Unit None B. Starter Inspection Step Action Reference Check security of attachment and electrical connections...
  • Page 98 24-00.3.8 Battery Inspection 24-00.3.8.1 Type of Maintenance Line 24-00.3.8.2 Minimum Level of Certification Pilot/Owner (P/O) 24-00.3.8.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Battery Inspection Step Action Reference Check for security, corrosion and general condition of battery tray, terminals and wirings Inspect for security of mounting and condition.
  • Page 99 CHAPTER 25 – EQUIPMENT/FURNISHINGS Contents 25-00.1 General 25-00.2 Maintenance Practices 25-00.2.1 Seat Uninstalling and Installing 25-00.2.2 Safety Belt Uninstalling and Installing 25-00.2.3 Access Panels Removal and Installation 25-00.2.4 Fabric Covers Removal and Installation 25-00.2.5 Carpets Removal and Installation 25-00.2.6 Seat Upholstery Removal and Installation 25-00.2.7 Seat Inspection SECTION 25-62 EMERGENCY LOCATOR TRANSMITTER...
  • Page 100 25-00.2 Maintenance Practices 25-00.2.1 Seat Uninstalling and Installing 25-00.2.1.1 Type of Maintenance Line 25-00.2.1.2 Minimum Level of Certification Pilot/Owner (P/O) 25-00.2.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Seat Uninstalling and Installing (Fig. 25-00-1) Step Action Reference Release the buckle 1 that fixes the seat belt...
  • Page 101 25-00.2.2 Safety Belt Uninstalling and Installing 25-00.2.2.1 Type of Maintenance Line 25-00.2.2.2 Minimum Level of Certification Pilot/Owner (P/O) 25-00.2.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Safety Belt Uninstalling and Installing (Fig. 25-00-2) Step Action Reference Unscrew 6 bolt-nut connections M6 (bolt (1), washer (3), nut (4)) that fix aluminum clamps (2) and reinforcement plates (5) to the main bulkhead.
  • Page 102 25-00.2.3 Access Panels Removal and Installation 25-00.2.3.1 Type of Maintenance Line 25-00.2.3.2 Minimum Level of Certification Pilot/Owner (P/O) 25-00.2.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Access Panels Removal and Installation (Fig. 25-00-3). Remove access panels to provide access to systems and structural components inspection in accordance with instructions below.
  • Page 103 Fig. 25-00-3 25-00.2.4 Fabric Covers Removal and Installation 25-00.2.4.1 Type of Maintenance Line 25-00.2.4.2 Minimum Level of Certification Pilot/Owner (P/O) Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 25-00-5 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 104 25-00.2.4.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Fabric Covers Removal and Installation (Fig. 25-00-4). Step Action Reference Free the lower 3 loops of the cover (1) from the pins (2) to provide access to luggage compartment.
  • Page 105 25-00.2.5 Carpets Removal and Installation 25-00.2.5.1 Type of Maintenance Line 25-00.2.5.2 Minimum Level of Certification Pilot/Owner (P/O) 25-00.2.5.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Carpets Removal and Installation (Fig. 25-00-5). Step Action Reference Velcro tapes are used for the carpets fixation on the cockpit floor. Fig.
  • Page 106 25-00.2.6 Seat Upholstery Removal and Installation 25-00.2.2.1 Type of Maintenance Line 25-00.2.2.2 Minimum Level of Certification Pilot/Owner (P/O) 25-00.2.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Seat Upholstery Removal (Fig. 25-00-6) Step Action Reference Unscrew nut (1) that fixes the head-rest (2). Unscrew two nuts (5) that fix buckle (3).
  • Page 107 25-00.2.7 Seat Inspection 25-00.2.2.1 Type of Maintenance Line 25-00.2.2.2 Minimum Level of Certification Pilot/Owner (P/O) 25-00.2.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Seat Inspection Step Action Reference Remove the seat. 25.2.1 Remove the upholstery. 25.2.6 Inspect the seat for damage, cracks, delaminations.
  • Page 108 SECTION 25-62 – EMERGENCY LOCATOR TRANSMITTER 25-62.1 General This section provides description and information about Emergency Locator Transmitter KANNAND ELT 406 AF. 25-62.2 Description ELT is installed on the airplane for transmitting of emergency signal in cases of emergency. ELT is located in the rear of the luggage compartment above the tunnel. The ELT Antenna is located in the top of the fuselage rear from the shut-out opening.
  • Page 109 25-62.3 Maintenance Practices 25-62.3.1 ELT Uninstalling and Installing 25-62.3.1.1 Type of Maintenance Line 25-62.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 25-62.3.1.3 Procedure Fig. 25-2 is described procedure for ELT installing and uninstalling A. Recommended Special Tools and Parts Item Quantity Unit None B.
  • Page 110 25-62.3.2 ELT Antenna Uninstalling and Installing 25-62.3.2.1 Type of Maintenance Line 25-62.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 25-62.3.2.3 Procedure Fig. 25-62-3 is described procedure for ELT Antenna installing and uninstalling A. Recommended Special Tools and Parts Item Quantity Unit None B.
  • Page 111 25-62.3.3 ELT and ELT Antenna Inspection 25-62.3.3.1 Type of Maintenance Line 25-62.3.3.2 Minimum Level of Certification Pilot/Owner (P/O) 25-62.3.3.3 Procedure The ELT and ELT Antenna inspection is described in ELT KANNAD installation manual. Document Title Document No. Revision Date Section Airplane Maintenance Manual –...
  • Page 112 CHAPTER 26 – FIRE PROTECTION Contents 26-00.1 General 26-00.2 Description 26-00.1 General This chapter provides information concerning extinguisher located in the pocket at the backside of the copilot seat backrest. Refer to fire extinguisher manufacturer’s manual for more data about the extinguisher. 26-00.2 Description ▲Warning: Every CTLS-LSA has the fire extinguisher in the pocket on the back of...
  • Page 113 CHAPTER 27 – FLIGHT CONTROLS Contents 27-00.1 General 27-00.2 Description 27-00.3 Control Surface Deflections SECTION 27-10 – AILERONS 27-10.1 General 27-10.2 Description 27.10.2.1 Aileron Trim 27-10.3 Maintenance Practices 27-10.3.1 Rigging of Aileron “Zero” Position 27-10.3.2 Measuring of Aileron Deflection 27-10.3.3 Aileron Deflection Adjustment 27-10.3.4 Aileron Controls Inspections...
  • Page 114 27-00.1 General This chapter provides description and information on Flight Controls. 27-00.2 Description The aircraft has dual controls, thus allowing operation from both seats. The dual controls cannot be separated. Even when the aircraft can be fully operated from both seats, the pilot in command is defined on the left hand seat.
  • Page 115 SECTION 27-10 – AILERONS 27-10.1 General This section provides description of the Aileron control system. 27-10.2 Description The ailerons are activated via push rods which run from the control stick through the tunnel to the mixer in the baggage compartment behind the main frame. In the mixer, at the upper end of the main bulkhead, the aileron input is coupled with the flap setting.
  • Page 116 Fig. 27-10-2 The fork rod connects left and right rod rockers in luggage compartment with two push- rods. Return springs are connected to fork rod, too. Fig. 27-10-3 Rod rockers are attached to flap rocker from the one side and from the other side mounted on guide pins attached to fuselage.
  • Page 117 Fig. 27-10-5 Left and right rod-rockers are connected to outer rockers of left and right wings with horizontal push-rods. Outer rockers are attached to root ribs of wings. Fig. 27-10-6 The two long push-rods are connected to the inner rockers, one in each wing. The inner rockers are attached to the rib of each wing.
  • Page 118 Fig. 27-10-8 The ailerons stop limits the control sticks movements. Ailerons stopper is a bush located on control sticks under torsion tube. The bush hampers to the torsion tube when control stick is deflected to the limit position. In case of need you can adjust ailerons stop installing the bushes with other diameter.
  • Page 119 Fig. 27-10-11 Rotating trim wheel you change tension of the right return spring. Left rotation is increase tension. Right – decrease. The left return spring seeks the balance of tension and rotates fork rod. It changes position of ailerons. 27-10.3 Maintenance Practices 27-10.3.1 Rigging of Aileron “Zero”...
  • Page 120 Fig. 27-10-12 Adjust ailerons position against the flaps by the vertical rods length adjusting (Fig. 27-10-12) and Wing short rod (Fig. 27-10-13). Fig. 27-10-13 27-10.3.2 Measuring of Aileron Deflection 27-10.3.2.1 Type of Maintenance Line 27-10.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-10.3.2.3 Procedure A.
  • Page 121 B. Measuring of Aileron Deflection Step Action Reference Aileron deflections are defined in the deflection table. 27.3 Set the flaps at cruise position “0” Deflect the aileron to upper extreme position by control stick. Measure distance between trailing edges of aileron and flap (Fig 27-10-14). Fig.
  • Page 122 Fig. 27-10-15 After each adjustment check the angles of aileron deflection. 27-10.3.2 27-10.3.4 Aileron Controls Inspections 27-10.3.4.1 Type of Maintenance Line 27-10.3.4.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-10.3.4.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B.
  • Page 123 SECTION 27-20 – RUDDER 27-20.1 General This section provides description of the Rudder control system. 27-20.2 Description The rudder is activated via control cables which are housed in a plastic sleeve in the tunnel and along the tail beam (Fig. 27-20-1). Fig.
  • Page 124 Fig. 27-20-3 The nose wheel steering is coupled fix to the rudder pedals, using two pushrods. This allows direct and precise steering when taxiing the aircraft. 27-20.2.1 Rudder Trim Rudder trim is activated by a trim wheel in the middle of the tunnel between the pilot and co-pilot.
  • Page 125 Item Quantity Unit None B. Rigging of Rudder “Zero” Position The adjustment is done by the movable stopper plate. To change neutral position of the rudder it is necessary to change position of stopper plate in centering fork KF27100200 (Fig. 27-20-5). Step Action Reference...
  • Page 126 B. Measuring of Rudder Deflection (Fig. 27-20-6) Step Action Reference Rudder deflections are defined in the deflection table. 27.3 Set rudder at neutral position Deflect rudder to extreme position by pedals. Measure travel range of the lowest point of the rudder trailing edge. Deflect rudder to another extreme position by pedals.
  • Page 127 necessary to unscrew stopper bolts out. To increase rudder deflection it is necessary to screw bolts in. Step Action Reference Remove the middle lower instrument panel 31.3.1.3 Loose lock nuts M6 Adjust stopper bolts position Check rudder deflection range 27-20.3.2 If necessary repeat step 2, 3 When adjusted tight lock nuts M6 27-20.3.4...
  • Page 128 27-20.3.5 Control Cable Tension Adjustment ▲Warning: After each centering device maintenance the tension of the control cables must be checked. ▲Warning: Make sure that the tips of turnbuckles are threaded in on not less than 8 mm. There are two methods of tension adjustment: coarse and fine. The coarse tension adjustment is performed by the nose wheel steering rods and the fine adjustment is performed by turnbuckles of control cables.
  • Page 129 27-20.3.6 Rudder Controls Inspections 27-20.3.6.1 Type of Maintenance Line 27-20.3.6.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-20.3.6.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Checking for Play Step Action Reference Fix the pedals at neutral positions. Slightly shake trailing edges of the rudder left and right.
  • Page 130 SECTION 27-40 – STABILATOR 27-40.1 General This section provides description of the Stabilator control system. 27-40.2 Description The CTLS-LSA has a drag-optimized Stabilator (all-moving) with an anti-tab. It is attached to a fuselage-mounted Stabilator pivot. An individually matched counter-weight, attached to the Stabilator pivot inside the fuselage, ensures full mass-balance.
  • Page 131 Fig. 27-40-2 The system is provided with stops. The stops are installed internally in the tunnel. The stops are done as pads set on threaded pin. The pads are locked with nuts. At extreme deflection of the control sticks the pads get contact with stopper plate Fig. 27-40-3. Document Title Document No.
  • Page 132 Fig. 27-40-3 27-40.2.1 Stabilator with Manual Trim Actuator (earlier models) Stabilator trim is adjusted with the trim wheel in the center console, next to the throttle. The trim indicator is located directly next to the trim wheel. The aircraft becomes nose heavy when the wheel is rotated forward and tail heavy when it is turned backward.
  • Page 133 Fig. 27-40-5 Fig. 27-40-6 27-40.2.2 Stabilator with Electrical Trim Actuator (newer models) Electric Pitch Trim Actuator (1) is installed to Stabilator Mounting Pivot (2) (see Fig. 27-40- 7) and replaces standard mechanical spindle drive. The kinematic system that is operated by this actuator is not changed compared to the basic aircraft.
  • Page 134 Fig. 27-40-7 Deflection of trim tab is controlled by rocker switch located at the throttle quadrant (see Fig. ). Fig. 27-40-8 The display is in the Dynon screen on the EMS page (see Fig. 24-40-9). Fig. 27-40-9 27-40.2.3 Adjustment of Stabilator with Electrical and Manual Trim For additional adjustment instructions for electrical and manual trim contact the aircraft manufacturer.
  • Page 135 27-40.3 Maintenance Practices 27-40.3.1 Stabilator Deflection Measuring 27-40.3.1.1 Type of Maintenance Line 27-40.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-40.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Digital level B. Stabilator deflection measuring Step Action Reference Stabilator deflections are defined in deflection table 27.3 Set the plane at parking brake...
  • Page 136 Fig. 27-40-12 Do step 4 in another direction 27-40.3.2 Stabilator Deflection Adjustment The Stabilator deflection range is adjusted by stoppers position. 27-40.3.2.1 Type of Maintenance Line 27-40.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-40.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit...
  • Page 137 Fig. 27-40-13 27-40.3.3 Measuring of Trim Tab Deflection 27-40.3.3.1 Type of Maintenance Line 27-40.3.3.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-40.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Measuring ruler B. Measuring of Trim Tab Deflection (Fig. 27-40-14). Step Action Reference...
  • Page 138 Fig. 27-40-14 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 27-40-9 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 139 27-40.3.4 Rigging of Trim Tab “Zero” Position The trim tab is factory adjusted so as the trailing edge of the trim tab coincides with trailing edge of the Stabilator when trim tab as well as Stabilator, are at neutral position. The trim tab is connected to the control unit by two push-pull rods (Fig.
  • Page 140 27-40.3.5 Stabilator Controls Inspections 27-40.3.5.1 Type of Maintenance Line 27-40.3.5.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-40.3.5.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Checking for Play Step Action Reference Fix the control stick at neutral positions. Slightly shake trailing edges of the Stabilator up and down.
  • Page 141 SECTION 27-50 – FLAPS 27-50.1 General This section provides description of the Flap Control System 27-50.2 Description The flaps are driven by a geared and self-locking electric motor and are activated from the flap control unit in the lower section of the instrument panel. The desired flap setting is selected with a lever switch.
  • Page 142 Fig. 27-50-2 Fig. 27-50-3 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 27-50-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 143 The transverse rod is connected to the flaps via tips (Fig. 27-50-4). The flaps tips are set to the transverse rod tips when wings attaching. Fig. 27-50-4 The transverse rod mechanically connects left and right flaps. This way the flaps are physically interconnected, left side to right side.
  • Page 144 The flap control circuit breaker is located directly next to the flap controls. It will pop if the flap servo is continuously over-loaded. As it is a thermal circuit breaker, it can take some time before it can be pushed back in. Fig.
  • Page 145 Turn KA6030210 (Transverse rod tube, right) and KA6030220 (Transverse rod tube, left) with respect to each other so that both flaps are aligned to the top of the fuselage. Fix position of the bolts С9996042 Bolt DIN 912 M5x45-8.8 with respect to the KA6030220 (Transverse rod tube, left) by the bolts C9996026 (Bolt DIN 912 M4x20-8.8).
  • Page 146 27-50.3.2 Measuring of Flap Deflection 27-50.3.2.1 Type of Maintenance Line 27-50.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-50.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit Ruler B. Measuring Flap Deflection (Fig. 27-50.8) Step Action Reference Flap deflections are defined in deflection table. 27.3 Set flap to negative deflection (Position -12°) Measure distance between same corners (lowest or topmost) on the rear edge...
  • Page 147 27-50.3.3 Flap Deflection Adjustment 27-50.3.31 Type of Maintenance Line 27-50.3.3.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-50.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Flap Deflection Adjustment (Fig. 27-50.9) Flap deflection can be adjusted by the flap control panel. Check flap angle of deflection after each adjustment.
  • Page 148 Fig. 27-50-9 27-50.3.4 Flap Controls Inspections 27-50.3.4.1 Type of Maintenance Line 27-50.3.4.2 Minimum Level of Certification LSA- Mechanic (LSAM) 27-50.3.4.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Checking for Play Step Action Reference Slightly shake trailing edges of the flap up and down. Make sure that the play of the trailing edge doesn’t exceed 5mm.
  • Page 149 Fig. 27-50-10 C. Inspection of Flap Control Microswitches (Fig. 27-50.11) Step Action Reference Set the flaps in position “30°” 27-00.3 Set the flap control switch in the flap position “-12° (-6°)”. While the actuator is moving press the upper limit switch by a screwdriver. The actuator must stop then.
  • Page 150 CHAPTER 28 – FUEL SYSTEM Contents 28-00.1 General 28-00.2 Description 28-00.3 Maintenance Practices 28-00.3.1 Fuel System Inspections 28-00.3.2 Fuel Pump Removal and Installation 28-00.3.3 Fuel Hoses and Lines Replacement 28-00.1 General This chapter provides description of the Fuel System. 28-00.2 Description The fuel system consists of: integrated in to each wing fuel tank with capacity of 65 l fuel lines...
  • Page 151 Excess fuel is pumped back to the gascolator. The Fuel System is presented schematically on the following diagram (Fig. 28-00-2). Filler cap Sloshing rib Sloshing rib Filler cap NACA nozzle Tank ventilation Tank ventilation NACA nozzle with ventilation with ventilation in winglet in winglet Tank vent connection left –...
  • Page 152 To open the fuel filler cap, the lever in the cap must be raised and turned 90° anti- clockwise. The cap can then be removed. The cap is properly shut when the lever is pressed down into position (Fig. 28-00-4). Fig.
  • Page 153 Fig. 28-00-5 The fuel tanks are vented via coupled tubes in the outer tank sections. The air is provided by NACA inlets on the outer side of each upper winglet (Fig. 28-00-6). The NACA located on the lower airfoil side of the upper winglets close to the trailing edge, where accumulation of humidity or ice is almost impossible due to aerodynamics.
  • Page 154 Fig. 28-00-7 The shutoff valve is installed before filter. That enables to close fuel line and perform filter maintenance what does not require fuel draining from the fuel tanks. The gascolator is installed in the engine compartment in the lowest point of the fuel system.
  • Page 155 28-00.3 Maintenance Practices 28-00.3.1 Fuel System Inspections 28-00.3.1.1 Type of Maintenance Line 28-00.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 28-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Fuel Filter Inspection Step Action Reference Inspect all fuel lines for damages, leakages, connections securing. Verify lines routing for kinks or restricted elbows.
  • Page 156 C. Gascolator Inspection Remove lock wire from Gascolator and unscrew is lower container. Clean gascolator lower container and inspect it for damages, cracks and scuffing marks. Clean gascolator net if required. Assemble gascolator in reversed direction order. D Shut off valve Inspection Remove lower instrument panel.
  • Page 157 28-00.3.2 Fuel Pump Removal and Installation 28-00.3.2.1 Type of Maintenance Line 28-00.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 28-00.3.2.3 Procedure ® Refer to the ROTAX Maintenance Manual valid for your individual engine. 28-00.3.3 Fuel Hoses and Lines Replacement 28-00.3.3.1 Type of Maintenance Line 28-00.3.3.2 Minimum Level of Certification LSA- Mechanic (LSAM)
  • Page 158 CHAPTER 31 – INSTRUMENT BOARD AND INDICATING SYSTEMS Contents 31-00.1 General 31-00.2 Description 31-00.3 Maintenance Practices 31-00.3.1 Instrumental Panel Uninstalling and Installing 31-00.3.2 Instruments Inspection 31-00.3.3 Instrument Panels Inspection 31-00.1 General This section provides description and information concerning maintenance of Instrument Board and indicating systems.
  • Page 159 Fig. 31-00-2 Pos. Manufacturer Type Description Winter 6 FMS 4 Analog airspeed indicator 3.25 in, km/h or kt Winter 4 FGH 10 Analog three pointer altimeter, 80 mm Winter Gr 1 Slip indicator, 58 mm Winter 5 STVM 5 Vertical speed indicator, 58 mm Garmin SL40 COM radio...
  • Page 160 31-00.3 Maintenance Practices 31-00.3.1 Instrumental Panel Uninstalling and Installing 31-00.3.1.1 Type of Maintenance Line 31-00.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 31-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Instrumental Panel Uninstalling Step Action Reference Switch off power: turn off all instruments;...
  • Page 161 31-00.3.2 Instruments Inspection 31-00.3.2.1 Type of Maintenance Line 31-00.3.2.2 Minimum Level of Certification Pilot/Owner (P/O) 31-00.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Instruments Inspection Step Action Reference Altimeter. Visually check altimeter for integrity and clean it. Analog Airspeed indicator.
  • Page 162 31-00.3.3 Instrument Panels Inspection 31-00.3.3.1 Type of Maintenance Line 31-00.3.3.2 Minimum Level of Certification Pilot/Owner (P/O) 31-00.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Instruments Inspection Step Action Reference Check the integrity of the panel (the panel must not be cracked) Check the bolts tightening that hold the panels (If the bolts are tightened not tight –...
  • Page 163 CHAPTER 32 – LANDING GEAR AND BRAKES Contents 32-00.1 General 32-00.2 Description SECTION 32-10 – MAIN LANDING GEAR 32-10.1 General 32-10.2 Description 32-10.3 Maintenance Practices 32-10.3.1 Fairing, Main Wheel Uninstalling and Installing 32-10.3.2 Main Wheel Uninstalling and Installing 32-10.3.3 Tire and Tube Inspection and Replacement 32-10.3.4 Main Strut Fairing Removal and Installation 32-10.3.5...
  • Page 164 This chapter provides description of the landing gear and brakes. 32-00.2 Description CT is equipped with conventional tricycle landing gear. The main gear legs made of high strength composite material are attached to the main bulkhead located behind the pilot seats.
  • Page 165 SECTION 32-10 – MAIN LANDING GEAR 32-10.1 General This section provides description and maintenance procedures for Main Landing Gear. 32-10.2 Description The main landing gear of the CTLS-LSA consists of two individual gear struts, two main wheels with brakes, wheel fairings and gear leg fairings. The main gear struts are made of composite materials.
  • Page 166 Fig. 32-10-2. View from the cabin side Fig. 32-10-3. View from the cabin side Fig. 32-10-4 The interface between main gear strut and fuselage is covered with a composite fairing to ensure good aerodynamic efficiency. The main wheels axles are attached directly to the main strut.
  • Page 167 32-10.3 Maintenance Practices 32-10.3.1 Fairing, Main Wheel Uninstalling and Installing The fairings of main wheels are attached in three point from the inner side and in one point from the outer side. Fig. 32-10-5 Fig. 32-10-6 Fig. Item Part Name Torque Reference Fairing, Main Wheel...
  • Page 168 32-10.3.1.1 Type of Maintenance Line 32-10.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 32-10.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Fairing, Main Wheel Uninstalling. Fig. 32-10-5, Fig. 32-10-6. Step Action Reference Unscrew one bolt item 2. Remove washer item 3. Unscrew three bolts item 1.
  • Page 169 32-10.3.2 Main Wheel Uninstalling and Installing Fig. 32-10-7 Fig. Item Part Name Torque Reference Main Wheel KF32100062 Brake disk part of set C9997204B Axle Nut part of set C9997204C Washer part of set C9997204C Cotter Pin part of set C9997204C 32-10-7 Screw 0.25"...
  • Page 170 B. Main Wheel Uninstalling (Fig. 32-10-7) Step Action Reference Remove cotter pin item 5. Unscrew Axle Nut item 3. Unscrew 3 Screws item 5. Detach brake disk item 2 from the wheel rim. Pull wheel out and remove from the axle item 9 C.
  • Page 171 Fig. Item Part Name Torque Reference Tire C9997212C Tube C9997212D Wheel, Valve Half part of set C9997204B Wheel, Brake part of set C9997204B Roller Bearing part of set C9997204B 32-10-8 Lock Nut 98 lb-in part of set C9997204B 11 Nm Washer Thick part of set C9997204B Bolt, Hex...
  • Page 172 32-10.3.4.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Main Strut Fairing Removal and Installation (Fig. 32-10-9) Step Reference Detach the Seal Tape from the Fairing, Main Strut and Fuselage. Unscrew two screws that fix the fairing to fuselage. Pull the main strut fairing along the main strut.
  • Page 173 32-10.3.5 Main Struts Removal and Installation 32-10.3.5.1 Type of Maintenance Line 32-10.3.5.2 Minimum Level of Certification LSA- Mechanic (LSAM) 32-10.3.5.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Main Struts Removal and Installation (Fig.). Step Reference Remove Main Strut Fairings.
  • Page 174 Set an airplane on a locating block. 07.2 Lift the tail of the fuselage so that the Main Wheel is at least 10’’ (25 sm.) off the ground. Insert the padded support securely just behind the Baggage Door (under the fuselage bottom).
  • Page 175 32-10.3.6 Main Gear Inspections 32-10.3.6.1 Type of Maintenance Line 32-10.3.6.2 Minimum Level of Certification LSA- Mechanic (LSAM) 32-10.3.6.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Main Struts Inspection. Step Reference Inspect the main struts for bending, damages, dents, cracks, paint peeling on the surface and especially at the mounting holes areas, integrity and circularity of the mounting holes.
  • Page 176 SECTION 32-20 – NOSE LANDING GEAR 32-20.1 General This section provides description and information concerning maintenance of Nose Landing Gear. 32-20.2 Description The nose landing gear is attached to the lower section of the big engine mount with bearings, to allow steering. The nose gear strut is designed as telescope with integral urethane spring elements.
  • Page 177 Fig. Item Part Name Torque Reference Nose Wheel KF32200201 Nose Fairing KF32200010 Big engine mount KF71200100 Frame 1 32-20-1 Rocker KF32200005 Cylinder, Shock KF32200110 Fork, Nose Wheel KF32200150 Polyurethane damper Element C9999158Z Rubber seal KF32200201 Fig. 32-20-2 Document Title Document No. Revision Date Section...
  • Page 178 32-20.3 Maintenance Practices Fig. 32-20-3 Fig. Item Part Name Torque Reference Rocker KF32200005 Bush KF32200006 Bolt M6 KF32200009 Rod, Left KF32200400 Rod, Right KF32200401 Self-locking nut M6 80 lb-in C9996334 32-20-3 9 Nm Rod End Bearing MM-M8 C999705D Self-locking nut M8 C9996336 Washer C9996565...
  • Page 179 32-20.3.1 Nose Gear Uninstalling and Installing For nose gear uninstalling and installing the two persons required. 32-20.3.1.1 Type of Maintenance Heavy 32-20.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 32-20.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B.
  • Page 180 32-20.3.2 Nose Wheel Fairing Uninstalling and Installing Fig. 32-20-4 Fig. Item Part Name Torque Reference Nose Fairing KF32200010 Protruded Pin KF32200024 Grommet C9997731G 32-20-4 Bolt M6 at the left side, C9996054 Bolt M6 at the right side, C9996059 Washer C9996565 Grommet C9997731D 32-20.3.2.1 Type of Maintenance...
  • Page 181 B. Nose Wheel Fairing Uninstalling (Fig. 32-20-4) Step Action Reference Unscrew two protruded pins item 2. Remove grommets item 3 Unscrew bolts M6 items 4, 5.Remove washers and grommets items 6, 7 Lift up fairing. Remove fairing. C. Nose Wheel Fairing Installing (Fig. 32-20-4) Step Action Reference...
  • Page 182 32-20.3.3.1 Type of Maintenance Line 32-20.3.3.2 Minimum Level of Certification LSA- Mechanic (LSAM) 32-20.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Nose Wheel Uninstalling (Fig. 32-20-5) Step Action Reference Unscrew self-locking nut M12, item 7 Remove axle, bush, spacers, washer items 4, 3, 5, 6.
  • Page 183 32-20.3.4 Tire and Tube Inspection and Replacement Fig. 32-20-6 Fig. Item Part Name Torque Reference Tire 7207W Tube 7207H Wheel Rim Left and right, part of set C9997204B 32-20-6 Roller Bearing part of set C9997204B Bolt 100lb-in part of set C9997204B 11Nm Lock Nut part of set C9997204B...
  • Page 184 B. Tire and Tube Inspection and Replacement (Fig. 32-20-6) Step Action Reference Uninstall nose wheel 32-20.3.3 Unscrew and remove three bolts item 5. Remove nuts item 6 Disconnect wheel rims item 3 Remove tire and tube items 1, 2 Inspect Tire and Tube. When necessary replace. Assemble main wheel in reversed direction order Install nose wheel 32-20.3.3...
  • Page 185 Fig. 32-20-7 Fig. Item Part Name Torque Reference Cylinder, Shock KF32200110 Fork, Nose Wheel KF32200150 Threaded Pin KF32200141 KF32200101 Support KF32200171 Washer KF32200176 32-20-7 O-ring, round C9997730F Self-locking nut M8 80 lb-in C9996336 9 Nm O-ring, flat C9997730P Washer C9996567 Polyurethane Damper Elements C9999158Z Document Title...
  • Page 186 32-20.3.6 Nose Gear Inspections 32-20.3.6.1 Type of Maintenance Line 32-20.3.6.2 Minimum Level of Certification LSA- Mechanic (LSAM) 32-20.3.6.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Visual Inspection Step Action Reference Inspect the strut and fork for damages, dents, cracks, paint detachment separation.
  • Page 187 SECTION 32-40 – BRAKES 32-40.1 General This section provides description and information concerning maintenance of Brake System. 32-40.2 Description The main wheels of the CTLS-LSA have hydraulic disc brakes. They are operated with the brake lever that is located in the throttle quadrant. Braking is only possible symmetric on both wheels.
  • Page 188 Only reinforced brake lines with metal fittings are used in an aircraft. The main cylinder is installed internally of the tunnel. The parking valve is done as combination of the valve and check valve. The PTFE tube connects main cylinder and header tank.
  • Page 189 The header tank is located in the luggage compartment and is attached to the main bulkhead. Fig. 32-40-3 Fig. 32-40-4 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 32-40-3 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 190 The opening in tunnel is covered with composite hatch. The hatch is provided with slot for brake valve. The stickers on the hatch shows valve position. Fig. 32-40-5 The brake line is connected to the main cylinder via metal fittings. Fig.
  • Page 191 Items and tightening torque Fig. Item Part Name Torque Reference Main cylinder C9997204F Brake Valve C9997204G Brake rod KF32400020 Handle activation KF32400011 Brake line part of set C9997209C Brake (caliper) part of set C9997204B Brake disk part of set C9997204B Rod end C9997006C Fuel filter...
  • Page 192 32-40.3 Maintenance Practices 32-40.3.1 Brakes Inspection 32-40.3.1.1 Type of Maintenance Line 32-40.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 32-40.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Brakes Inspection Step Action Reference Clean and check hydraulic cylinders, activation handle and connections for condition, braking fluid leaks, for cracks and corrosion, securing of components.
  • Page 193 CHAPTER 33 – LIGHTS Contents 33-00.1 General SECTION 33-40 – EXTERIOR LIGHTS 33-40.1 General 33-40.2 Exterior Lights Thiesen 33-40.2.1. Description 33-40.2.2 Maintenance Practices 33-40.2.2.1 Wing Tip Position Lights Uninstalling and Installing 33-40.2.2.2 Rear Position Lights Uninstalling and Installing 33-40.2.2.3 Anti Collision Light Uninstalling and Installing 33-40.2.2.4 Position Lights and Anti Collision Light Inspection 33-40.3...
  • Page 194 SECTION 33-40 – EXTERIOR LIGHTS 33-40.1 General This section provides description and information concerning maintenance of exterior lights. 33-40.2 Exterior Lights Thiesen 33-40.2.1. Description Fig. 33-40-1 shows location of the exterior lights. Fig. 33-40-1 Pos. Description Left Position Light Right Position Light Rear Position Light Anti Collision Light The position lights system consists of the three components:...
  • Page 195 Fig. 33-40-2 Fig. 33-40-3 Fig. 33-40-4 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 33-40-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 196 33-40.2.2 Maintenance Practices 33-40.2.2.1 Wing Tip Position Lights Uninstalling and Installing 33-40.2.2.1.1 Type of Maintenance Line 33-40.2.2.1.2 Minimum Level of Certification Pilot/Owner 33-40.2.2.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Left and Right Position Lights Uninstalling Step Action Reference...
  • Page 197 Fig. 33-40-6 Fig. Item Part Name Torque Reference Socket ball isol. red 4mm 0.25-1sqmm C9997134 33-40-6 Plug ball isol. red 4mm 0.25-1sqmm C9997131 Fig. 33-40-7 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 33-40-4 Approval Ref.:...
  • Page 198 33-40.2.2.2 Rear Position Lights Uninstalling and Installing 33-40.2.2.2.1 Type of Maintenance Line 33-40.2.2.2.2 Minimum Level of Certification Pilot/Owner 33-40.2.2.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Rear Position Light Uninstalling Step Action Reference Using hex-head screwdriver 3mm unscrew bolts item 2 that hold the rear position light (Fig.
  • Page 199 Fig. 33-40-9 Fig. Item Part Name Torque Reference Socket ball isol. red 4mm 0.25-1sqmm C9997134 33-40-9 Plug ball isol. red 4mm 0.25-1sqmm C9997131 Fig. 33-40-10 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 33-40-6 Approval Ref.:...
  • Page 200 33-40.2.2.3 Anti Collision Light Uninstalling and Installing 33-40.2.2.3.1 Type of Maintenance Line 33-40.2.2.3.2 Minimum Level of Certification Pilot/Owner 33-40.2.2.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Anti Collision Light Uninstalling Step Action Reference Using hex-head screwdriver 3mm unscrew bolts item 2 that hold the anti collision light (Fig.
  • Page 201 Fig. 33-40-12 Fig. Item Part Name Torque Reference Socket ball isol. red 4mm 0.25-1sqmm C9997134 33-40-12 Plug ball isol. red 4mm 0.25-1sqmm C9997131 Fig. 33-40-13 33-40.2.2.4 Position Lights and Anti Collision Light Inspection 33-40.2.2.4.1 Type of Maintenance Line 33-40.2.2.4.2 Minimum Level of Certification Pilot/Owner 33-40.2.2.4.3 Procedure Visual checking of operating.
  • Page 202 33-40.3 Exterior Lights Whelen (newer models) 33-40.3.1 Description Fig. 33-40-1 shows location of the exterior lights. Fig. 33-40-14 Pos. Description Left Position Light Right Position Light The position lights system consists of the two components: Position Light Left, Fig. 33-40-14; Position Light Right, Fig.
  • Page 203 33-40.3.2.1.2 Minimum Level of Certification Pilot/Owner 33-40.3.2.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Left and Right Position Lights Uninstalling and Installing Step Action Reference Unscrew Screw (2 pcs.) item 6 (Fig. 33-40-16). Remove Retainer item 5 (Fig. 33-40-16). Remove Lens item 7 (Fig.
  • Page 204 Fig. 33-40-16 Fig. Item Part Name Torque Reference Base plate part of set 7159Y Assembly, 12V LED Wingtip Light Green 71733 part of set 7159Y Assembly, 12V LED Wingtip Light Red 71733 part of set 7159Y Screw, 4-40 x 5/16 P100FH MS24693-C3 part of set 7159Y 33-40-16 Retainer, Lens Model 71733...
  • Page 205 Fig. 33-40-17 33-40.3.2.2 Position Lights and Anti Collision Light Inspection 33-40.3.2.2.1 Type of Maintenance Line 33-40.3.2.2.2 Minimum Level of Certification Pilot/Owner 33-40.3.2.2.3 Procedure Visual checking of operating. If any of the LEDs is not operating properly, or does not operate replace it in accordance with procedure described above. Document Title Document No.
  • Page 206 CHAPTER 34 – AVIONIC Contents 34-00.1 General 34-00.2 Description 34-00.3 Maintenance Practices 34-00.3.1 Avionic Units Uninstalling and Installing 34-00.3.2 Avionic Units Inspection SECTION 34-20 – PITOT/STATIC SYSTEM 34-20.1 General 34-20.2 Description 31-20.3 Maintenance Practices 34-20.3.1 Pitot/Static Ports Uninstalling and Installing 34-20.3.2 Inspection of Pitot/Static System 34-00.1 General...
  • Page 207 34-00.3 Maintenance Practices 34-00.3.1 Avionic Units Uninstalling and Installing 34-00.3.1.1 Type of Maintenance Line 34-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 34-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Radio Garmin SL40/Transponder GTX330 Uninstalling and Installing Step Action Reference...
  • Page 208 C. GPS Garmin AERA 500 Uninstalling and Installing Step Action Reference Using hex-head screwdriver 3mm unscrew 4 bolts that hold the upper middle 31.3.1.3 panel. To remove the Garmin AERA 500 from the AirGizmos panel dock push upward fixing clamp and pull out the unit (see Fig. 34-00-3). Disconnect Power-Data cable and GPS antenna from Garmin AERA 500 (see Fig.
  • Page 209 Fig. 34-00-5 Fig. 34-00-6 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 34-00-4 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 210 E. Dynon Flight Deck LRU Uninstalling and Installing Step Action Reference Relevant Follow instructions provided by Dynon. Dynon manuals 34-00.3.2 Avionic Units Inspection 34-00.3.2.1 Type of Maintenance Line 34-00.3.2.2 Minimum Level of Certification Pilot/Owner (P/O) 34-00.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit...
  • Page 211 SECTION 34-20 – PITOT/STATIC SYSTEM 34-20.1 General This section provides description and information concerning maintenance of Pitot/Static system. 34-20.2 Description The airplane may be configured in different ways: 1. Analog instrumentation In this case air data is provided to analog instruments (Fig. 34-20-2): - Airspeed indicator (ASI);...
  • Page 212 Inside the fuselage the line is routed forward along the root rib and down the right “A” pillar into the instrument console. Inside the instrument console the line is split using T connectors, as necessary per installed equipment. Location of pressure lines is described on Fig. 34-20-1. Fig.
  • Page 213 Fig. 34-20-2 Fig. 34-20-3 B. New Static Port Installation In the newer installation, the static port on the fuselage belly is removed. Static pressure is provided from a ring of static bores on the pitot probe, installed to the wing. Lines routing is identical to the routing of total pressure, in parallel and just to the relevant ports.
  • Page 214 31-20.3 Maintenance Practices 34-20.3.1 Pitot/Static Ports Uninstalling and Installing 34-20.3.1.1 Type of Maintenance Line 34-20.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 34-20.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Pitot tube Uninstalling Step Action Reference Take the Pitot tube out of the wing, Pitot tube is removed by hand pressure ahead from the wing leading edge as shown Fig.
  • Page 215 Fig. 34-20-5 Fig. Item Part Name Torque Reference L-adapter, conic A-Wek-6/4-1/8-MSv C9997417E KF31200102 Washer KF31200103 34-20-5 Sealing washer KF31200104 Flange (Static port) KF31200101 Captive nut M12 part of set C9997417E Static pressure line 34-20.3.2 Inspection of Pitot/Static System 34-20.3.2.1 Type of Maintenance Line 34-20.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM)
  • Page 216 B. Inspection of Pitot/Static System Step Action Reference Take the Pitot tube out of the wing, Pitot tube is removed by hand pressure ahead from the wing leading edge as shown Fig. 34-20-4. Clean it (remove insect, debris and so on) using a stick. Disconnect Pitot/AOA pressure lines Disconnect Static pressure line from Static Port by unscrewing captive nut M12 item 6 as shown Fig.
  • Page 217 CHAPTER 51 – STANDARD PRACTICES AND STRUCTURES Contents 51-00.1 General 51-00.2 Description SECTION 51-10 – INVESTIGATION 51-10.1 General 51-10.2 Damage Classes 51-10.3 Types of Damage 51-10.4 Inspection Techniques 51-10.5 Further Inspection SECTION 51-20 – REPAIR PROCESSES 51-20.1 General 51-20.1 Painting and Coating SECTION 51-30 –...
  • Page 218 SECTION 51-10 – INVESTIGATION 51-10.1 General This section provides description of damages classes and types and presents an overview of applicable damage investigation techniques. 51-10.2 Damage Classes There are following accepted classes of damage: Damage Class 1 Major structural damage that requires the partial replacing of a structural component, or the damage to a large area, or to a highly stressed component are classified as the Class 1 damages.
  • Page 219 (or other layer/component), then the skin is disbonded and you must repair the structure. In some cases you shall cut inspection holes in the structure to perform the test correctly. In this case you shall contact Flight Design for specific instructions. Document Title Document No.
  • Page 220 SECTION 51-20 – REPAIR PROCESSES 51-20.1 General This section provides description of damages classes and types and presents an overview of applicable damage investigation techniques. When further information is needed please contact the aircraft manufacturer for further instructions. 51-20.1 Painting and Coating Since full strength of the fiber composite structure has only been shown up to a temperature of 54°C (129°F), the outer surface of the airplane must be painted white.
  • Page 221 Fig. 51-20-1 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 51-20-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 222 SECTION 51-30 – MATERIALS When needed please contact the aircraft manufacturer for further instructions. Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 51-30-1 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 223 SECTION 51-70 – REPAIRS When needed please contact the aircraft manufacturer for further instructions. Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 51-70-1 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 224 CHAPTER 52 – DOORS Contents 52-00.1 General 52-00.2 Description 52-00.3 Maintenance Practices 52-00.3.1 Door Inspection SECTION 52-30 – BAGGAGE DOORS 52-30.1 General 52-30.2 Description 52-30.3 Maintenance Practices 52-30.3.1 Door Inspection 52-00.1 General The doors are made of composite material and are not a structural components of an aircrafts 52-00.2 Description The door hinged at the top and open like gull wing-door.
  • Page 225 Fig. Item Part Name Torque Reference Door Gas spring Hinge 52-00-2 Door seal Latching mechanism Sliding window vent Fig. 52-00-2 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 52-00-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 226 52-00.3 Maintenance Practices 52-00.3.1 Door Inspection 52-00.3.1.1 Type of Maintenance Line 52-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 52-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Door Inspection Step Action Reference Inspect for smooth operation and fit. Inspect the skin, hinges, gas struts, latching Inspect apertures protection of latching mechanism for integrity operating (Fig.
  • Page 227 SECTION 52-30 – BAGGAGE DOORS 52-30.1 General The baggage doors are made of composite material and are not a structural components of an aircrafts 52-30.2 Description The baggage doors are installed to the baggage compartment access hatches behind the main frame. The lock device consists of the two fixed pins located on the lower flange and latching mechanism on the top.
  • Page 228 52-30.3 Maintenance Practices 52-30.3.1 Door Inspection 52-30.3.1.1 Type of Maintenance Line 52-30.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 52-30.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Door Inspection Step Action Reference Inspect for operation and fit. Inspect door skin, attachment pins, and latching mechanism.
  • Page 229 CHAPTER 53 – FUSELAGE Contents 53-00.1 General 53-00.2 Description 53-00.3 Maintenance Practices 53-00.3.1 Fuselage Inspection 53-00.1 General This chapter provides description of fuselage. 53-00.2 Description The fuselage is built in a stressed skin design, supported by few with frames. The main bulkhead separates pilot’s compartment from luggage compartment.
  • Page 230 The structure of the fuselage is built using composite materials. Mostly sandwich structures are used due to the low weight and high strength capabilities. In some areas monolithic lay-up is used without application of sandwich foam. The composite structure makes use of carbon, aramid and glass fibers materials with uni- and multidirectional fibers.
  • Page 231 53-00.3 Maintenance Practices 53-00.3.1 Fuselage Inspection 53-00.3.1.1 Type of Maintenance Line 53-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 53-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Drain Holes Inspection Step Action Reference Check the drain holes for obstructions (Fig. 53-00-3). Check the paint condition and cleanliness.
  • Page 232 C. Control Cables and Push-Pull Guides Inspection Step Action Reference Check the rudder control cable guides for delamination (Fig. 53-00-4) Fig. 53-00-4 Check the push-pull cable guides for delamination (Fig. 53-00-5). Fig. 53-00-5 C. Troubleshooting Step Action Reference In case when any abnormalities during inspection was found contact manufacturer for further instructions.
  • Page 233 CHAPTER 55 – STABILIZERS Contents 55-00.1 General 55-00.2 Description SECTION 55-10 – STABILATOR 55-10.1 General 55-10.2 Description 55-10.3 Maintenance Practices 55-10.3.1 Stabilator Installation and Removal 55-10.3.2 Balancing of the Stabilator counter weight 55-10.3.3 Stabilator and Trim Tab Inspection SECTION 55-30 – UNDERFIN 55-30.1 General 55-30.2...
  • Page 234 SECTION 55-10 – STABILATOR 55-10.1 General This section provides description of the Stabilator 55-10.2 Description The Stabilator consists of skins and inner structural components. The skins are made of two halves designed as Carbon fibers sandwich construction. In some areas monolithic lay-up is used without application of sandwich foam. The inner components are designed as Carbon/Glass fibers structure without sandwich foam application.
  • Page 235 The Stabilator is attached to the steel mounting bracket. The bracket is installed to the fuselage by the use axle. The installation principle presented in the Fig. 55-10-2. Fig. 55-10-2 Fig. 55-10-3 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 55-10-2...
  • Page 236 55-10.3 Maintenance Practices 55-10.3.1 Stabilator Installation and Removal 55-10.3.1.1 Type of Maintenance Line 55-10.3.1.2 Minimum Level of Certification Part 145, Part M, Part 66 CS 55-10.3.1.3 Procedure Aircraft in basic configuration is equipped with mechanically actuated trim tab system. Optionally instead of mechanically actuated system can be installed electrically actuated trim tab system.
  • Page 237 Attach the bracket to Stabilator matching the holes in the bracket (3) with holes in the upper and the lower skins of the Stabilator (Fig. 55-10-5). Secure the bracket by bolts C9996259N (Bolt DIN 931 M6x110-8.8). Check Stabilator balance as follows. Set the Stabilator so that it can revolve on its axis under its own weight.
  • Page 238 C. Installation Step Action Reference Check lock rings (Fig. 55-10-6) that secure the bearings on both sides of the fuselage are present. Check inner cage of the bearings for free rotation. Replace bearings, if necessary. Fig. 55-10-6 Lubricate the axle of rotation. Make sure that the threaded parts of the axle are not lubricated.
  • Page 239 Attach the bearing body by bolts and nuts (during adjustment it is allowable to use non- self-locking nuts, which have to be replace for final installation). Install the Stabilator into the bracket and check angle of “cross incidence” with respect to the fuselage roof. Repeat described above operations, if necessary, to get the roof and Stabilator parallel (The difference should not be more than 0.5°)
  • Page 240 Fig. 55-10-7 55-10.3.1.3.2 Configuration with Electrical Actuator of Trim A. Checking of Balancing Prior Stabilator installation, check it for balancing out of fuselage as follows. This verification strongly recommended in any case when for the system Stabilator – counterweight with bracket – trim tab the changing of any of the following components is possible: the weight of any component or position of the center of gravity for any component.
  • Page 241 upper and the lower skins of the Stabilator (Fig. 55-10-9). Secure the bracket by bolts C9996259N (Bolt DIN 931 M6x110-8.8). Check Stabilator balance as follows. Set the Stabilator so that it can revolve on its axis under its own weight. If the upper skin does not align horizontally when stopped, 55-10.3.2 correct balancing.
  • Page 242 B. Installation Step Action Reference Check condition of bearing in stabilator support (Fig. 55-10-10) and forg-roil of housing around bearing. Check inner cage of the bearings for free rotation. Replace bearings ready mounting, if necessary. Fig. 55-10-10 Lubricate the axle of rotation. Make sure that the threaded parts of the axle are not lubricated.
  • Page 243 allowable to use non- self-locking nuts, which have to be replace for final installation). Install the Stabilator into the bracket and check angle of “cross incidence” with respect to the fuselage roof. Repeat described above operations, if necessary, to get the roof and Stabilator parallel (The difference should not be more then 0.5°) Secure bearing bodies by tightening new self-locking nuts M5 to torque 94 lb-in /...
  • Page 244 55-10.3.2 Balancing of the Stabilator counter weight 55-10.3.1.1 Type of Maintenance Line 55-10.3.1.2 Minimum Level of Certification Part 145, Part M, Part 66 CS 55-10.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Balancing of the Stabilator (Fig. 55-20-11) Step Action Reference...
  • Page 245 55-10.3.3 Stabilator and Trim Tab Inspection 55-10.3.3.1 Type of Maintenance Line 55-10.3.3.2 Minimum Level of Certification Part 145, Part M, Part 66 CS 55-10.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Checking the Stabilator and Trim Tab Installation for Play (Fig. 55-20-12) Step Action Reference...
  • Page 246 C. Drain Holes Inspection (Fig. 55-20-13) Step Action Reference Check the drain holes provided on the lower surface of Stabilator skin for blockage. Fig. 55-20-13 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 06-Dec-19 55-10-13 Approval Ref.:...
  • Page 247 SECTION 55-30 – UNDERFIN 55-30.1 General This section provides description of Underfin. 55-30.2 Description The underfin designed as Carbon fibers structure without sandwich foam application. The underfin is attached to the fuselage tail boom with bolts. There are 3 attachment points, per side, Fig.
  • Page 248 Fig. 55-30-2 B. Installation Step Action Reference Installation is done in a reverse order. Use bonding liquid middle strength for bolts (3) installation. 55-30.3.2 Underfin Inspections 57-51.3.2.1 Type of Maintenance Line 57-51.3.2.2 Minimum Level of Certification Pilot/Owner (P/O) 57-51.3.1.3 Procedure A.
  • Page 249 SECTION 55-40 – RUDDER 55-40.1 General This section provides description of Rudder. 55-40.2 Description The rudder consists of skins and inner structural components. The skins are made of two halves designed as Carbon fibers sandwich construction. In some areas monolithic lay-up is used without application of sandwich foam. The inner components are designed as Carbon/Glass fibers structure without sandwich foam application.
  • Page 250 When rudder installed the upper pin of rudder is set in bearings of upper fuselage steel bracket. The pin is secured with cotter pin. The lower pin of rudder is set in bearing of the lower fuselage bracket. The pin of lower bracket is secured with self-locking nut.
  • Page 251 55-40.3 Maintenance Practices 55-40.3.1 Rudder Installation and Removal 55-40.3.1.1 Type of Maintenance Heavy 55-40.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 55-40.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Rudder Installation and Removal ● Note: the rudder must be installed to the aircraft prior to Stabilator installation, due to accessibility reasons.
  • Page 252 Prior to that the bushings (2) are to be installed from both sides of the thimble and tightened by the screw М6х30 (3) to the rudder lower support (4). Use lock liquid of middle strength Loctite 243 for the screw. Fig.
  • Page 253 55-40.3.2 Rudder Inspections 55-40.3.1.1 Type of Maintenance Line 55-40.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 55-40.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Drain Holes Inspection (Fig. 55-40-5) Step Action Reference Check the drain hole provided on the lower surface of rudder skin for blockage. Fig.
  • Page 254 CHAPTER 56 – WINDOWS Contents 56-00.1 General 56-00.2 Description 56-00.1 General This chapter provides description of windows. 56-00.2 Description All windows are made from contoured Plexiglas. The windows are glues to the composite structure, to allow a smooth aerodynamic shape. The windows in both doors are equipped with sliding windows.
  • Page 255 CHAPTER 57 – WING Contents 57-00.1 General 57-00.2 Description SECTION 57-00 – WING STRUCTURE 57-00.1 General 57-00.2 Description 57-00.3 Maintenance Practices 57-00.3.1 Wing Removal and Installation 57-00.3.2 Wing Inspection 57-00.3.3 Access Panel Removal and Installation 57-00.3.4 Tie Down Points Removal and Installation SECTION 57-51 –...
  • Page 256 SECTION 57-00 – WING STRUCTURE 57-00.1 General This section provides description of wing structure and maintenance practices. 57-00.2 Description The structure of the wing is build using composite materials. Mostly sandwich structures are used due to the low weight and high strength capabilities. The composite structure makes use of carbon, aramid and glass fibers materials with uni- and multidirectional fibers.
  • Page 257 There are steel shear pins attached to the root ribs. The wings attach with these pins to bushes at the fuselage root rib. Fig. 57-00-2 The wing spars are fixed inside the fuselage spar box by means of 2 easy-removable main bolts (Fig.
  • Page 258 Fig. 57-00-4 The wing skin is provided with inspection hatch (Fig. 57-00-5) covered with transparent cover by means of 4 screws. Use this hatch and cut-outs along the tailing edge to perform inspection in accordance with check list provided in Section 05-20.2.7. 57-00.3 Maintenance Practices 57-00.3.1 Wing Removal and Installation...
  • Page 259 Lubricate all metal details before connecting: the flap pin (2) (Fig. 57-00-7); pins on the wing root rib (1) (Fig. 57-00-9, Fig. 57-00-10); the main bolts (1) (Fig. 57-00-14). Set each wing with the tongue into the spar box with clearance 0.75-1ft between the fuselage and the wing root rib (Fig.
  • Page 260 Fig. 57-00-8 Match the hole of the aft bushing KA1000101 on the fuselage with the pin on the wing root rib (1) (Fig. 57-00-9). Fig. 57-00-9 Match the hole in the forward bushing KA1000110 of the fuselage with the pin of the wing root rib (1) (Fig.
  • Page 261 Set the pins of the wing root rib up to the stop into the forward and aft bushings on the fuselage. Take care that the flap pin gets into the groove of the tip (Fig. 57-00-7). Note that the pins can be set properly into the bushings by moving of the wing back and forth (Fig.
  • Page 262 Fig. 57-00-14 Fig. 57-00-15 Repeat steps 13-14 for the second main bolt. Secure the main bolts with the cap and bolt, e.g. set the caps (1) onto the main bolts and fix them by bolts М8x35 (Fig. 57-00-16). Torque value for the main bolts is 200 lb- in / 22.5 Nm.
  • Page 263 Fig. 57-00-16 Match the holes in the tip of the rod (1) with holes of the right wing aileron lever (2) (Fig. 57-00-17). Fig. 57-00-17 Aileron connection: Fix the rod (1) in the lever (2) with the bolt М6x30 С9996259А (3). Use only new self-locking nuts M6 (Fig.
  • Page 264 Fig. 57-00-18 Verification: -Make sure the main bolts are properly tight, check torque of the screws. -Make sure the control rod bolts are secured and marked with anti-sabotage lacquer -Make sure the fuel lines are properly secured with hose clamps Check the fuel flow rate.
  • Page 265 57-00.3.2 Wing Inspection 57-00.3.2.1 Type of Maintenance Line 57-00.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 57-00.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Wing Brackets Inspection Step Action Reference Inspect the wing brackets for security and play (Fig. 57-00-19). In case of play torque the bolts.
  • Page 266 B. Checking Fuselage-Wing Connection for Tangential Play Step Action Reference Make sure that there is no play while moving the wing in accordance with Fig. 57-00-21. Fig. 57-00-21 C. Drain Holes Inspection Step Action Reference Check the drain holes provided on the lower surface of wing skin for blockage. Fig.
  • Page 267 57-00.3.3 Access Panel Removal and Installation 55-20.3.3.1 Type of Maintenance Line 55-20.3.3.2 Minimum Level of Certification Pilot/Owner (P/O) 55-20.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Access Panel Removal and Installation (Fig. 57-00-23). Remove the wing hatch to provide access to the inner wing structure and aileron control components.
  • Page 268 Disconnect the OAT sensor from the hatch (when installed). Remove plastic plugs that close access holes in the trailing edge (Fig. 57-00-24). Fig. 57-00-24 Installation of panels is done in reverse order. 57-00.3.4 Tie Down Points Removal and Installation 57-00.3.4.1 Type of Maintenance Line 57-00.3.4.2 Minimum Level of Certification Pilot/Owner (P/O)
  • Page 269 SECTION 57-51 – FLAP 57-51.1 General This section provides description of flap structure and maintenance practices. 57-51.2 Description The flaps are driven by an electrical spindle motor and are activated via the flap control in the lower section of the instrument panel. The desired flap setting is selected with a torque switch.
  • Page 270 Fig. 57-51-1 Fig. Item Part Name Torque Reference Bolt DIN 912 M6x25 Bolt M6x29 57-51-1 Washer Washer Self-locking nut M6 57-51.3 Maintenance Practices 57-51.3.1 Flap Installation and Removal 57-51.3.1.1 Type of Maintenance Heavy 57-51.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 57-51.3.1.3 Procedure A.
  • Page 271 Step Action Reference Match the hole in the root flap bracket (1) (KW2040010R for the right wing, or KW2040010L for the left wing) with the hole in the bushings of the bearing of the wing bracket No.1 (2) (KW2010010 for the right wing, or KW2020010 for the left wing) and connect them by the bolt (3) KА2020006 (but do not fix the bolt by the nut (5) (C9996334, Self-locking nut DIN 985-M6, regular), Fig.
  • Page 272 Fig. 57-51-4 Using a washer С99965604 (Washer DIN 125 A2B-6.4 mm) and the nut (5) (C9996334, Self-locking nut DIN 985-M6, regular) fix the bolts. While installing the wings, make sure that the pin at the root flap bracket (1) (KА2040010L(R)) got into connection with the tip of the flap rod (2) KА6030200 (Transverse rod).
  • Page 273 57-51.3.2 Flap Inspections 57-51.3.2.1 Type of Maintenance Line 57-51.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 57-51.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Drain Holes Inspection (Fig. 57-51-7) Step Action Reference Inspect the drain holes provided on the lower surface of the flap skin for the blockage. Fig.
  • Page 274 SECTION 57-52 – AILERON 57-52.1 General This section provides description of aileron structure and maintenance practices. 57-52.2 Description The ailerons are made of aramid top and bottom skins, carbon web and three glass fiber composite ribs. The aileron is attached to the wing by two hinged brackets. Fig.
  • Page 275 57-52.3 Maintenance Practices 57-52.3.1 Aileron Installation and Removal 57-52.3.1.1 Type of Maintenance Line 57-52.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 57-52.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Aileron Installation Step Action Reference Match hole on the root aileron bracket (1) with hole in the bushing of the bearing of the wing bracket (2) and connect them by the bolt (3) (do not fix the bolt by the nut (4), Fig.
  • Page 276 the bolt С9996219 (Bolt DIN 7991 M6x35). Set the bearing С9997006А (Rod end bearing, ext. thread GA6) by the bolt С9996219 (Bolt DIN 7991 M6x35 A2) onto the aileron root rib. Use washers С9996565 (Washer DIN 9021-6.4 mm VZ) and С9996504 (Washer DIN 125 A2B-6.4 mm) as shown (Fig.
  • Page 277 Fig. 57-52-6 Connect the aileron rod (1) (KA6020030R) with internal bellcrank (Fig. 57-52-5). Engage, but do not tighten the nut on the bolt. Set the external bellcrank (2) KА6020040 so that the line between the rod (1) attachment hole and bellcrank axle of rotation is perpendicular to the root rib (Fig.
  • Page 278 57-52.3.2 Aileron Inspections 57-51.3.2.1 Type of Maintenance Line 57-51.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 57-51.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Drain Holes Inspection (Fig. 57-52-8) Step Action Reference Inspect the drain holes provided on the lower surface of the aileron skin for the blockage.
  • Page 279 CHAPTER 61 – PROPELLER Contents 61-00.1 General 61-00.2 Description 61-00.3 Maintenance Practices 61-00.3.1 Spinner Installation and Removal 61-00.3.2 Propeller Removal and Installation 61-00.3.3 Further Propeller Maintenance 61-00.1 General This chapter provides description of the propeller. 61-00.2 Description The CTLS-LSA is available with following propellers: Neuform CR3-65-(IP)-47-101.6, 3 blade composite propeller, ground adjustable...
  • Page 280 61-00.3 Maintenance Practices For propeller inspection and maintenance instructions refer to the latest issue of maintenance manual provided by the propeller manufacturer. 61-00.3.1 Spinner Installation and Removal 61-00.3.1.1 Type of Maintenance Line 61-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 61-00.3.1.3 Procedure A.
  • Page 281 Unscrew 6 Screws M5, item 4, and move Spinner 1 forward along the Spinner Axis 3 to remove it. Inspect Spinner Disk 2 and Spinner 1 for damages, paint delaminating. Inspect the Spinner Axis 3 for playing and screws securing. Inspect for cracks and corrosion.
  • Page 282 61-00.3.2 Propeller Removal and Installation 61-00.3.2.1 Type of Maintenance Line 61-00.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 61-00.3.2.3 Procedure Refer to the maintenance manual provided by the propeller manufacturer for the specific propeller. 61-00.3.3 Further Propeller Maintenance For any further maintenance procedures affecting the propeller, propeller blades or propeller hub refer to the maintenance manual provided by the propeller manufacturer for the specific propeller.
  • Page 283 CHAPTER 71 – ENGINE Contents 71-00.1 General 71-00.2 Description 71-00.3 Maintenance Practices 71-00.3.1 Engine Cowlings Removal 71-00.3.2 Engine Mount Inspection 71-00.3.3 Air Induction Inspection 71-00.3.4 Starter Replacement 71-00.3.5 Generator Replacement 71-00.3.6 Other Engine Maintenance 71-00.1 General This chapter provides description of the engine systems. 71-00.2 Description ®...
  • Page 284 71-00.3 Maintenance Practices 71-00.3.1 Engine Cowlings Removal The upper and lower cowlings cover engine compartment. The cowlings are connected together and attached to the fuselage. The cowlings provided with quick fasteners. The upper cowling provided with an inspection hatch for access to oil and coolant tanks. The lower cowling provided with air-inlets for engine cooling, air induction, cabin heating and mounting place for landing light (optionally).
  • Page 285 71-00.3.1.1 Type of Maintenance Line 71-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 71-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Engine Cowlings Removal Step Action Reference Set the aircraft to chokes and switch the ignition OFF 71.2.1 Unscrew 13 Camlock Studs 7: Press and turn with the screwdriver to quarter-turn;...
  • Page 286 71-00.3.2 Engine Mount Inspection The engine is attached to the primary aircraft structure via strong steel engine mount. The small engine mount is attached directly to engine. The small engine mount is attached to the Big Engine mount via rubber chock mounts. Fig.
  • Page 287 71-00.3.2.1 Type of Maintenance Line 71-00.3.2.2 Minimum Level of Certification LSA- Mechanic (LSAM) 71-00.3.2.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Engine Mount Inspection Step Action Reference Remove upper and lower cowlings 71.2.1 Lift the forward fuselage by pushing down the tail at the narrowest part so that the Nose Wheel is at least 10’’...
  • Page 288 Fig. 71-00-3. Air Induction and Carburetors heating Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 71-00-6 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 289 71-00.3.3.1 Type of Maintenance Line 71-00.3.3.2 Minimum Level of Certification Pilot/Owner (P/O) 71-00.3.3.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None A. Carburetors heating system inspection Step Action Reference Remove upper and lower cowlings 71.2.1 Check Aeroduct hoses for damage, security of attachments and condition. Check the Carburetors and Airbox installation.
  • Page 290 Fig. Item Part Name Torque Reference Dust Filter Box KF28001020 Cover KF28001023 Air filter C9997789N Clamp part of set C9997789N 71-00-4 Screw M5 C9996161 Rivet Nut M5 C9996834 Screw M5 C9996035 Self-locking Nut C9996333 Washer C9996563 B. Dust Filter Inspection. Step Action Reference...
  • Page 291 71-00.3.6 Other Engine Maintenance This maintenance practice covers all maintenance items that affect the core engine directly, that are not otherwise defined within this AMM and that are appropriately defined within the applicable Rotax engine maintenance manual. 71-00.3.6.1 Type of Maintenance Heavy 71-00.3.6.2 Minimum Level of Certification Minimum LSA- Mechanic (LSAM).
  • Page 292 CHAPTER 73 – ENGINE FUEL AND CONTROL Refer to the maintenance manual provided by the engine manufacturer for your engine for description and maintenance instructions on the engine-mounted portion of the fuel system. Document Title Document No. Revision Date Section Airplane Maintenance Manual –...
  • Page 293 CHAPTER 74 – IGNITION Refer to the maintenance manual provided by the engine manufacturer for your engine for description and maintenance instructions on the ignition system including spark plugs. Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 74-00-1...
  • Page 294 CHAPTER 75 – COOLING Contents 75-00.1 General 75-00.2 Description 75-00.3 Maintenance Practices 75-00.3.1 Cooling Inspection 75-00.3.2 Cooling Hoses and Lines Replacement 75-00.1 General This chapter provides description and information concerning maintenance of engine cooling. 75-00.2 Description The engine is provided with liquid cooling. The coupled water and oil radiators are installed in front of the engine just behind the air-inlet.
  • Page 295 Fig. 75-00-2. Cooling system diagram with thermostat From the top of the cylinder heads the coolant passes on to the expansion tank. Since the standard location of the radiator is below engine level, the expansion tank located on top of the engine allows for coolant expansion. The expansion tank is closed by a pressure cap (with excess pressure valve and return valve).
  • Page 296 Fig. 75-00-3. Cooling System Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 75-00-3 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 297 75-00.3 Maintenance Practices 75-00.3.1 Cooling Inspection 75-00.3.1.1 Type of Maintenance Line 75-00.3.1.2 Minimum Level of Certification Pilot/Owner (P/O) 75-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Cooling Inspection Step Action Reference Inspect connections for leaks. Check coolant level.
  • Page 298 Shock mount Oil Radiator Fig. 75-00-5. Radiators Unit mounting Remove clamp from overflow bottle and disconnect the hose from nipple. Drain coolant in clean container. Connect compression pump to hose free end and provide overpressure 0.2 bar/3 psi for one hour.
  • Page 299 CHAPTER 76 – ENGINE CONTROLS Contents 76-00.1 General 76-00.2 Description 76-00.3 Maintenance Practices 76-00.3.1 Throttle Box Inspection 76-00.1 General This chapter provides description and information concerning maintenance of engine controls. 76-00.2 Description The throttle quadrant is located in the center pedestal, just behind the lower instrument panel.
  • Page 300 Fig. 76-00-2 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 76-00-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 301 Fig. Item Part Name Torque Reference Main Plate KF76000151 Covering Plate KF76000001 Screw ISO 7380 M5x16 C9996162 Screw ISO 7380 M5x12 C9996161 Grip KF76000132 Grip KF76000131 Bolt DIN 7991 M6x35 A2-70 C9996219 Grip KF32400010 Grip KF32400012 Bolt DIN 7991 M6x30 A4 C9996218A Bolt DIN 912 M4x35-8.8 C9996029...
  • Page 302 76-00.3 Maintenance Practices 76-00.3.1 Throttle Box Inspection 76-00.3.1.1 Type of Maintenance Line 76-00.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 76-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Throttle Box Inspection (Fig. 76-00-2). Step Action Reference Unscrew 4 bolt M5 (3, 4) that fix the covering plate (2).
  • Page 303 CHAPTER 77 – ENGINE INDICATING For maintenance instructions regarding the engine indicating system contact the aircraft manufacturer. Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 77-00-1 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 304 CHAPTER 78 – EXHAUST Contents 78-00.1 General 78-00.2 Description 78-00.3 Maintenance Practices 78-00.3.1 Exhaust Muffler and Pipes Removal 78-00.3.2 Exhaust Muffler and Pipes Inspection 78-00.1 General This chapter provides description and information concerning maintenance of engine exhaust. 78-00.2 Description The powerplant exhaust system consists of the muffler and exhaust pipes. The exhaust gases from cylinders arrive to muffler via exhaust elbows.
  • Page 305 Fig. Item Part Name Torque Reference Forward exhaust pipe, right KF78000010 Rear exhaust pipe, right KF78000020 Forward exhaust pipe, left KF78000030 78-00-1 Rear exhaust pipe, left KF78000040 Muffler KF78000050 Spring Spring 12 Nm C9996035 78-00.3 Maintenance Practices 78-00.3.1 Exhaust Muffler and Pipes Removal 78-00.3.1.1 Type of Maintenance Line 78-00.3.1.2 Minimum Level of Certification...
  • Page 306 B. Exhaust Muffler and Pipes Inspection Step Action Reference Inspect exhaust system for damages and missing parts. Checks attachment Nuts 7 and Springs 6 for securing and fit. Inspect exhaust pipes and mounting flanges for cracks, corrosion and leakages. Remove muffler with exhaust pipes. Inspect muffler for cracks, corrosion and leakages.
  • Page 307 CHAPTER 79 – OIL SYSTEM Contents 79-00.1 General 79-00.2 Description 79-00.3 Maintenance Practices 79-00.3.1 Oil System Inspection 79-00.3.2 Oil Hoses and Lines Replacement 79-00.1 General This chapter provides description and information concerning maintenance of engine oil system. 79-00.2 Description The oil system is available in two variants: with oil thermostat;...
  • Page 308 Fig. 79-00-2. Oil System diagram Fig. Item Part Name Torque Reference Engine ROTAX® 912 S/ULS C9997789Z/C9997791Y Oil pump C9993515J Oil filter C9997793R Oil thermostat C9997793Y Oil tank C9997791I 79-00-1 79-00-2 Radiators Unit KF79000050 Oil hose C9997792D Fuel hose (vent line) C9993184G Oil pressure sensor C9997798O...
  • Page 309 Fig. 79-00-3 Fig. 79-00-4 Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 79-00-3 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 310 79-00.3 Maintenance Practices 79-00.3.1 Oil System Inspection 79-00.3.1.1 Type of Maintenance Line 79-00.3.1.2 Minimum Level of Certification LSA- Mechanic (LSAM) 79-00.3.1.3 Procedure A. Recommended Special Tools and Parts Item Quantity Unit None B. Oil System Inspection Step Action Reference Inspect connections for leaks. Check oil level.
  • Page 311 APPENDIX I – EQUIPMENT MANUFACTURER INFORMATION The following equipment manufacturer issued manuals are delivered together with the aircraft, and are valid for the specific aircraft S/N. It is the responsibility of the aircraft operator, to verify the sources identified by the equipment manufacturer for possible updates made available through the equipment manufacturer.
  • Page 312 Aircraft S/N Call Sign Issuing Document Document Title Rev. Name Signature Company Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 App I-2 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...
  • Page 313 Aircraft S/N Call Sign Issuing Document Document Title Rev. Name Signature Company Document Title Document No. Revision Date Section Airplane Maintenance Manual – CTLS-LSA AF 0480 0015 15-Jul-15 App I-3 Approval Ref.: Approved on the basis of Manufacturer Self Declaration...

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