Flight Design CT-LSA Maintenance Manual

1.12 Tire Inflation Pressure ............................................................................................................. 1-10 1.13 Approved Fluids and Capacities ............................................................................................. 1-10 1.14 Recommended Fastener Torque Values and Bolts Installation .............................................. 1-11 1.15 General Safety Information ..................................................................................................... 1-12 1.16 Instructions for Reporting Service Difficulties ......................................................................... 1-13 2 Minimum Levels of Certification: ...................................................................................................... 2-1 2.1 General...................................................................................................................................... 2-1 2.2 Levels of certification ................................................................................................................. 2-1 2.3 Required certification level for maintenance procedures .......................................................... 2-2 3 Aircraft Inspections .......................................................................................................................... 3-1 3.1 Aircraft Records......................................................................................................................... 3-2 3.2 Run-up ....................................................................................................................................... 3-3 3.3 Post-Run-up .............................................................................................................................. 3-4 3.4 Propulsion System .................................................................................................................... 3-5 3.5 Fuselage .................................................................................................................................... 3-6 3.6 Wings ........................................................................................................................................ 3-7 3.7 Empennage ............................................................................................................................... 3-8 3.8 Landing Gear ............................................................................................................................. 3-9 3.9 Cabin and Baggage Compartment.......................................................................................... 3-10 3.10 Inspection Completion ............................................................................................................. 3-12 4 Structures......................................................................................................................................... 4-1 4.1 Wing .......................................................................................................................................... 4-1 4.1.1 Wing Structure ..................................................................................................................... 4-1 4.1.2 Wing Installation and Removal ............................................................................................ 4-2 4.1.2.1 Tools Required ............................................................................................................ 4-2 4.1.2.2 Parts and Materials Required ..................................................................................... 4-2 4.1.2.3 Type of Maintenance ................................................................................................... 4-2 4.1.2.4 Minimum Level of Certification .................................................................................... 4-2 4.1.2.5 Wing Installation .......................................................................................................... 4-2 4.1.2.6 Wing Removal ............................................................................................................. 4-9 4.1.2.7 Verification Required ................................................................................................... 4-9 4.2 Landing Gear ........................................................................................................................... 4-10 4.2.1 Nose Landing Gear ............................................................................................................ 4-10 4.2.1.1 Tools Required .......................................................................................................... 4-10 4.2.1.2 Materials Required .................................................................................................... 4-10 4.2.1.3 General...................................................................................................................... 4-10 4.2.1.4 Inspections ................................................................................................................ 4-11 4.2.1.4.1 Type of Maintenance ........................................................................................... 4-11 4.2.1.4.2 Minimum Level of Certification ............................................................................ 4-11 4.2.1.4.3 Visual Inspection .................................................................................................. 4-11 4.2.1.4.4 Shock Absorber Inspection .................................................................................. 4-12 4.2.1.4.5 Fork Inspection .................................................................................................... 4-12 4.2.1.4.6 Nose Wheel Inspection ........................................................................................ 4-12 4.2.1.5 Nose Gear Removal (Replacement) ......................................................................... 4-13 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: vi AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 4.2.1.5.1 Type of Maintenance ........................................................................................... 4-13 4.2.1.5.2 Minimum Level of Certification ............................................................................. 4-13 4.2.1.5.3 Fork Removal ....................................................................................................... 4-13 4.2.1.5.4 Before Installation ................................................................................................ 4-14 4.2.1.5.5 Fork Installation .................................................................................................... 4-14 4.2.1.5.6 Fork Replacement ................................................................................................ 4-15 4.2.1.5.7 Shock Absorber ................................................................................................... 4-15 4.2.1.6 Nose Wheel ............................................................................................................... 4-16 4.2.1.6.1 Type of Maintenance ........................................................................................... 4-16 4.2.1.6.2 Minimum Level of Certification ............................................................................. 4-16 4.2.1.6.3 Nose Wheel Removal and Installation ................................................................. 4-16 4.2.2 Main Landing Gear............................................................................................................. 4-18 4.2.2.1 Tools Required .......................................................................................................... 4-18 4.2.2.2 Materials Required .................................................................................................... 4-18 4.2.2.3 General ...................................................................................................................... 4-19 4.2.2.4 Inspection .................................................................................................................. 4-19 4.2.2.4.1 Type of Maintenance ........................................................................................... 4-19 4.2.2.4.2 Minimum Level of Certification ............................................................................. 4-19 4.2.2.4.3 Visual inspection .................................................................................................. 4-19 4.2.2.4.4 Wheel Inspection ................................................................................................. 4-19 4.2.2.5 Main Wheel Fairing Removal (Replacement) ........................................................... 4-19 4.2.2.5.1 Type of Maintenance ........................................................................................... 4-19 4.2.2.5.2 Minimum Level of Certification ............................................................................. 4-19 4.2.2.5.3 Procedure............................................................................................................. 4-20 4.2.2.6 Main Wheel Removal and Installation ....................................................................... 4-21 4.2.2.6.1 Type of Maintenance ........................................................................................... 4-21 4.2.2.6.2 Minimum Level of Certification ............................................................................. 4-21 4.2.2.6.3 Wheel Brake Line Disconnecting ......................................................................... 4-21 4.2.2.6.4 Main Wheel Removal ........................................................................................... 4-21 4.2.2.6.5 Before Installation ................................................................................................ 4-22 4.2.2.6.6 Main Wheel Installation ........................................................................................ 4-22 4.2.2.7 Removal (Replacement) of Main Strut Fairing .......................................................... 4-23 4.2.2.7.1 Type of Maintenance ........................................................................................... 4-23 4.2.2.7.2 Minimum Level of Certification ............................................................................. 4-23 4.2.2.8 Main Gear Struts Removal and Installation ............................................................... 4-24 4.2.2.8.1 Type of Maintenance ........................................................................................... 4-24 4.2.2.8.2 Minimum Level of Certification ............................................................................. 4-24 4.2.2.8.3 Procedure............................................................................................................. 4-24 4.2.2.9 Wheel Inspection and Maintenance .......................................................................... 4-25 4.2.2.9.1 Type of Maintenance ........................................................................................... 4-25 4.2.2.9.2 Minimum Level of Certification ............................................................................. 4-25 4.2.2.9.3 Procedure............................................................................................................. 4-25 4.2.3 Brake System ..................................................................................................................... 4-27 4.2.3.1 Tools Required .......................................................................................................... 4-27 4.2.3.2 Materials Required .................................................................................................... 4-27 4.2.3.3 Inspection .................................................................................................................. 4-27 4.2.3.3.1 Type of Maintenance ........................................................................................... 4-27 4.2.3.3.2 Minimum Level of Certification ............................................................................. 4-27 4.2.3.3.3 General ................................................................................................................ 4-27 4.2.3.3.4 Inspection of Wheel Brakes ................................................................................. 4-28 4.2.3.3.5 Inspection of Brake Controls ................................................................................ 4-29 4.2.3.4 Filling Brake System with Fluid ................................................................................. 4-31 4.2.3.4.1 Type of Maintenance ........................................................................................... 4-31 4.2.3.4.2 Minimum Level of Certification ............................................................................. 4-31 4.2.3.4.3 Procedure............................................................................................................. 4-31 4.2.3.5 Brake Pads Replacement.......................................................................................... 4-32 4.2.3.5.1 Type of Maintenance ........................................................................................... 4-32 4.2.3.5.2 Minimum Level of Certification ............................................................................. 4-32 4.2.3.5.3 Procedure............................................................................................................. 4-32 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: vii AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 4.3 Flight Controls ......................................................................................................................... 4-33 4.3.1 Aileron ................................................................................................................................ 4-33 4.3.1.1 New design of aileron control system. ...................................................................... 4-34 4.3.1.2 Tools Required .......................................................................................................... 4-35 4.3.1.3 Materials Required .................................................................................................... 4-35 4.3.1.4 General...................................................................................................................... 4-35 4.3.1.5 Inspection .................................................................................................................. 4-35 4.3.1.5.1 Type of Maintenance ........................................................................................... 4-35 4.3.1.5.2 Minimum Level of Certification ............................................................................ 4-35 4.3.1.5.3 Bracket Inspection ............................................................................................... 4-36 4.3.1.5.4 Wing bracket bearings inspection ........................................................................ 4-36 4.3.1.5.5 Rods / Bellcranks inspection ............................................................................... 4-37 4.3.1.6 Aileron Installation ..................................................................................................... 4-37 4.3.1.6.1 Type of Maintenance ........................................................................................... 4-37 4.3.1.6.2 Minimum Level of Certification ............................................................................ 4-37 4.3.1.7 Aileron Adjustment .................................................................................................... 4-42 4.3.1.7.1 Type of Maintenance ........................................................................................... 4-42 4.3.1.7.2 Minimum Level of Certification ............................................................................ 4-42 4.3.1.7.3 Rigging Aileron “Zero” Position ............................................................................ 4-42 4.3.1.7.4 Aileron Deflection Adjustment ............................................................................. 4-44 4.3.1.7.5 Measuring Aileron Deflection ............................................................................... 4-45 4.3.1.8 Verification of Aileron Installation and Adjustment .................................................... 4-47 4.3.2 Flaps .................................................................................................................................. 4-48 4.3.2.1 Tools Required .......................................................................................................... 4-48 4.3.2.2 Materials Required .................................................................................................... 4-48 4.3.2.3 General...................................................................................................................... 4-49 4.3.2.4 Inspection .................................................................................................................. 4-49 4.3.2.4.1 Type of Maintenance ........................................................................................... 4-49 4.3.2.4.2 Minimum Level of Certification ............................................................................ 4-49 4.3.2.4.3 Bracket Inspection ............................................................................................... 4-49 4.3.2.4.4 Wing bracket bearings inspection ........................................................................ 4-50 4.3.2.4.5 Rods / Bellcranks inspection ............................................................................... 4-50 4.3.2.5 Flap Installation ......................................................................................................... 4-50 4.3.2.5.1 Type of Maintenance ........................................................................................... 4-50 4.3.2.5.2 Minimum Level of Certification ............................................................................ 4-50 4.3.2.5.3 Procedure ............................................................................................................ 4-51 4.3.2.6 Flap Adjustment ........................................................................................................ 4-53 4.3.2.6.1 Type of Maintenance ........................................................................................... 4-53 4.3.2.6.2 Minimum Level of Certification ............................................................................ 4-53 4.3.2.6.3 Rigging “Zero” Position of the Flaps .................................................................... 4-53 4.3.2.6.4 Flap Deflection Adjustment .................................................................................. 4-55 4.3.2.6.5 Measuring Flap Deflection ................................................................................... 4-56 4.3.2.7 Inspection of Flap Control Microswitches ................................................................. 4-59 4.3.2.7.1 Type of Maintenance ........................................................................................... 4-59 4.3.2.7.2 Minimum Level of Certification ............................................................................ 4-59 4.3.2.7.3 Procedure ............................................................................................................ 4-59 4.3.3 Rudder ............................................................................................................................... 4-60 4.3.3.1 Tools Required .......................................................................................................... 4-60 4.3.3.2 Materials Required .................................................................................................... 4-60 4.3.3.3 Rudder Installation and Removal .............................................................................. 4-60 4.3.3.3.1 Type of Maintenance ........................................................................................... 4-60 4.3.3.3.2 Minimum Level of Certification Required ............................................................. 4-60 4.3.3.3.3 Procedure ............................................................................................................ 4-60 4.3.3.4 Rudder Deflection Adjustment .................................................................................. 4-63 4.3.3.4.1 Type of Maintenance ........................................................................................... 4-63 4.3.3.4.2 Minimum Level of Certification ............................................................................ 4-63 4.3.3.4.3 Measuring Rudder Deflection .............................................................................. 4-64 4.3.3.4.4 Rigging Rudder Neutral Position ......................................................................... 4-66 4.3.3.4.5 Adjusting of Control Cable Tension ..................................................................... 4-67 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: viii AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 4.3.3.4.6 Fine Adjustment ................................................................................................... 4-68 4.3.3.4.7 Coarse Adjustment .............................................................................................. 4-68 4.3.3.5 Verification of Rudder Installation and Adjustment ................................................... 4-69 4.3.4 Stabilator ............................................................................................................................ 4-69 4.3.4.1 Tools Required .......................................................................................................... 4-71 4.3.4.2 Parts and Materials Required .................................................................................... 4-71 4.3.4.3 General ...................................................................................................................... 4-71 4.3.4.4 Stabilator Installation and Removal ........................................................................... 4-71 4.3.4.4.1 Type of Maintenance ........................................................................................... 4-71 4.3.4.4.2 Minimum Level of Certification ............................................................................. 4-71 4.3.4.4.3 Procedure............................................................................................................. 4-71 4.3.4.5 Stabilator Adjustment ................................................................................................ 4-77 4.3.4.5.1 Type of Maintenance ........................................................................................... 4-77 4.3.4.5.2 Minimum Level of Certification ............................................................................. 4-77 4.3.4.5.3 Measuring Stabilator Deflection ........................................................................... 4-78 4.3.4.5.4 Measuring of Trim Tab Deflection and Adjustment ............................................. 4-81 4.3.4.6 Balancing of the Stabilator Balancer ......................................................................... 4-83 4.3.4.6.1 Type of Maintenance ........................................................................................... 4-83 4.3.4.6.2 Minimum Level of Certification ............................................................................. 4-83 4.3.4.6.3 Procedure............................................................................................................. 4-83 4.3.4.7 Verification of Stabilator Installation and Adjustment ................................................ 4-84 4.4 Structural Repair ...................................................................................................................... 4-85 4.4.1 Type of Maintenance.......................................................................................................... 4-85 4.4.2 Minimum Level of Certification ........................................................................................... 4-85 4.4.3 Repair Procedures ............................................................................................................. 4-85 4.5 Painting and Coating ............................................................................................................... 4-85 4.5.1 Tools needed to accomplish the task ................................................................................. 4-85 4.5.2 The parts needed to perform the task ................................................................................ 4-85 4.5.3 Type of Maintenance.......................................................................................................... 4-85 4.5.4 Minimum Level of Certification ........................................................................................... 4-85 4.5.5 Puttying .............................................................................................................................. 4-85 4.5.6 Priming ............................................................................................................................... 4-86 4.5.7 Painting .............................................................................................................................. 4-86 4.5.8 Polishing ............................................................................................................................. 4-86 4.5.9 Method of Verification ........................................................................................................ 4-86 5 Engine .............................................................................................................................................. 5-1 5.1 Engine Systems and Accessories ............................................................................................. 5-1 5.2 Rotax 912ULS Engine ............................................................................................................... 5-1 5.3 Carb Heat Control...................................................................................................................... 5-2 5.3.1 Tools Required ..................................................................................................................... 5-2 5.3.2 Materials Required ............................................................................................................... 5-2 5.3.3 Type of Maintenance............................................................................................................ 5-2 5.3.4 Minimum Level of Certification ............................................................................................. 5-2 5.3.5 General ................................................................................................................................ 5-2 5.3.6 Inspection of Carburetor Heater Control .............................................................................. 5-2 6 Fuel System ..................................................................................................................................... 6-1 6.1 General ...................................................................................................................................... 6-1 6.2 Tools Required .......................................................................................................................... 6-3 6.3 Materials Required .................................................................................................................... 6-3 6.4 General System Inspection ....................................................................................................... 6-3 6.4.1 Type of Maintenance............................................................................................................ 6-3 6.4.2 Minimum Level of Certification ............................................................................................. 6-3 6.4.3 Procedure ............................................................................................................................. 6-3 6.5 Fuel Flow Check ........................................................................................................................ 6-4 6.5.1 Type of Maintenance............................................................................................................ 6-4 6.5.2 Minimum Level of Certification ............................................................................................. 6-4 6.5.3 Checking of Fuel Flow Rate ................................................................................................. 6-4 6.5.4 Simulation of In-Flight Engine Restart ................................................................................. 6-4 6.6 Intake Filter / Side Access Panel ............................................................................................... 6-6 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: ix AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 6.6.1 Type of Maintenance ........................................................................................................... 6-6 6.6.2 Minimum Level of Certification ............................................................................................. 6-6 6.6.3 Procedure ............................................................................................................................ 6-6 6.7 Fuel Filter .................................................................................................................................. 6-8 6.7.1 Type of Maintenance ........................................................................................................... 6-8 6.7.2 Minimum Level of Certification ............................................................................................. 6-8 6.7.3 Procedure ............................................................................................................................ 6-8 6.8 Gascolator ................................................................................................................................. 6-9 6.8.1 Type of Maintenance ........................................................................................................... 6-9 6.8.2 Minimum Level of Certification ............................................................................................. 6-9 6.8.3 Procedure ............................................................................................................................ 6-9 7 Propeller........................................................................................................................................... 7-1 7.1 Type of Maintenance ................................................................................................................. 7-1 7.2 Minimum Level of Certification .................................................................................................. 7-1 7.3 Propeller Maintenance Procedures ........................................................................................... 7-1 8 Utility Systems ................................................................................................................................. 8-1 8.1 Tools Required .......................................................................................................................... 8-1 8.2 Materials Required .................................................................................................................... 8-1 8.3 Cabin Heat System ................................................................................................................... 8-1 8.3.1.1 Type of Maintenance ................................................................................................... 8-1 8.3.1.2 Minimum Level of Certification .................................................................................... 8-1 8.3.1.3 Procedure .................................................................................................................... 8-1 9 Instruments and Avionics................................................................................................................. 9-1 9.1 Tools Required .......................................................................................................................... 9-1 9.2 Parts Required .......................................................................................................................... 9-1 9.3 Instrument Maintenance ............................................................................................................ 9-1 9.3.1 Type of Maintenance ........................................................................................................... 9-1 9.3.2 Minimum Level of Certification ............................................................................................. 9-1 9.3.3 General ................................................................................................................................ 9-1 9.3.4 Glass Cockpit Dynon EFIS 100 ........................................................................................... 9-1 9.3.5 Glass Cockpit Dynon EMS D120 ......................................................................................... 9-1 9.3.6 Analog Airspeed Indicator .................................................................................................... 9-2 9.3.7 Analog One Pointer Altimeter .............................................................................................. 9-2 9.3.8 Magnetic Compass with Deviation Table ............................................................................ 9-2 9.3.9 Flap position indicator .......................................................................................................... 9-2 9.3.10 Hobbs Hour Meter ........................................................................................................... 9-2 9.3.11 Radio Garmin SL30 with VOR functionality .................................................................... 9-2 9.3.12 Radio Garmin SL40 installed with antenna ..................................................................... 9-2 9.3.13 Transponder Garmin installation ..................................................................................... 9-2 9.3.14 Altitude Encoder ACK A30 (Classic) or Dynon (Advanced) ............................................ 9-3 9.3.15 GPS Garmin 496 ............................................................................................................. 9-3 9.3.16 ELT Ameriking AK450 ..................................................................................................... 9-3 9.3.17 Intercom PM 3000 A with aux music input and connection to GPS Audio...................... 9-3 9.4 Inspection of Pitot & Static Port ................................................................................................. 9-4 9.4.1 Type of Maintenance ........................................................................................................... 9-4 9.4.2 Minimum Level of Certification ............................................................................................. 9-4 9.4.3 Procedure ............................................................................................................................ 9-4 9.5 Special Equipment .................................................................................................................... 9-5 10 Electrical System ........................................................................................................................... 10-1 10.1 Tools Required ........................................................................................................................ 10-1 10.2 Materials Required .................................................................................................................. 10-1 10.3 General .................................................................................................................................... 10-1 10.3.1 Inspection ...................................................................................................................... 10-5 10.3.1.1 Type of Maintenance ................................................................................................. 10-5 10.3.1.2 Minimum Level of Certification .................................................................................. 10-5 10.3.1.3 Procedure .................................................................................................................. 10-5 10.4 Battery Replacement ............................................................................................................... 10-5 10.4.1 Type of Maintenance ..................................................................................................... 10-5 10.4.2 Minimum Level of Certification ...................................................................................... 10-5 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: x AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 10.4.3 Procedure ...................................................................................................................... 10-5 Appendix I . Template for Trim Tab Deflection Angles Measurement ......................................................AI-1 Appendix II. Adjustment report ................................................................................................................AII-1 Appendix III . Service Difficulty Report Form ..........................................................................................AIII-1 Appendix IV . MATCO Brake System .................................................................................................... AIV-1 Appendix V . Equipment Manufacturers Operating and Maintenance Information ................................ AV-1 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-1 AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 1 General This maintenance and inspection procedures manual provides all standard maintenance and inspection procedures needed to keep the aircraft airworthy. This manual also states the certification requirements for the persons performing each task. Maintenance tasks exceeding the scope of this manual are possible but require prior coordination with and approval by the manufacturer. The Flight Design CTLS is a three-axis control, high-wing, and two seats light sport aircraft of normal scheme with a cruciform tail. The primary structures are made of carbon fiber reinforced plastic. The aircraft is equipped with an all-moving stabilator with a trim tab and tricycle landing gear with a steerable nose- wheel. Federal rules require minimum certification levels of the mechanics perfoming individual maintenance tasks on an S-LSA aircraft to be defined by the airframe manufacturer. Refer to chapter 2 for the definition of the levels of certification applied throughout this manual. On each individual task you will find the allocation of level of certification. WARNING: Use only alkali-free products when cleaning your composite aircraft. For more information, refer to chapter 1.3 Care and Cleaning of your CT. 1.1 Approval The contents of this manual is approved on the basis of Manufacturer Self Declaration against the applicable ASTM industry standard. 1.2 Certification Basis The aircraft is in compliance with ASTM F2245. The engines Rotax 912 ULS is in compliance with ASTM F2339. The engine Rotax 912 ULS is Type Certified in compliance with FAR 33 Amdt. 15. This AMM is generated in compliance with ASTM F2483, and is part of the Required Product Information per ASTM F2745. The revision level of the standards applicable to the specific S/N is identified on the aircraft’s Statement of Compliance. 1.3 Manufacturer Flight Design GmbH Zum Tower 4 01917 Kamenz Germany www.flightdesign.com airworthiness@flightdesign.com 1.4 Recovery of Certification Data If the original manufacturer will lose the ability to support the make and model of this aircraft, you can recover certification documentation through the following contact: EUA Engineering Ukraine Ltd. Rabochaya 82a 73000 Kherson Ukraine Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-2 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.5 Care and cleaning of your CT Care must be taken when cleaning modern aircraft built with composite materials. Many products have been developed to clean a specific type of material and may be unsuitable or even damaging to others. Using the wrong product may damage your aircraft or its structures. Affected parts may be plainly visible or may be hidden from view. The type of damage can vary from the simply unsightly to the outright dangerous. You must always read the instructions for your cleaning products before using them. If you should have any questions about a product’s suitability please contact your local dealer. Each structure has its own cleaning requirements. The basic airframe and wing structure Composite aircraft are typically constructed of a sandwich of a structural material (Fiberglass-Carbon Fiber or Kevlar) over a foam core. The Flight Design CTLS is made up of a Carbon fiber-foam-Carbon fiber and Kevlar laminate sandwich which is filled with polyester filler, sanded and painted with two-part urethane paint. The foam core of the wings is partially Rohacell foam which was chosen for its stiffness and resistance to fuel. The fuselage core is Airex foam which allows the contours for the CTLS fuselage. The Rohacell foam, while highly resistant to fuel, is not resistant to strong Alkali cleaners or even water with very high alkali content. Therefore Flight Design requires that the cleaners used on the CTLS be PH neutral. Cleaners, such as Fantastik®, Formula 409®, Carbonex® and Castrol Super Clean®, which are otherwise good Alkali cleaning products, should not be used on the CTLS. The use of this category cleaner can dissolve the foam core of the sandwich leaving a dented looking area that must be repaired and re-painted. Please note that the wing spars of the CTLS are sealed in epoxy and fiberglass and cannot be damaged in this manner. The windshield and side windows The windows of the CTLS are tinted, heat molded acrylic (also known as Plexiglas®). While durable, they must be carefully cleaned to avoid scratching the surface. Never use an abrasive pad, abrasive pastes or even dirty rags when cleaning the window surfaces. Always flush the window surface with water to remove as much dust and dirt before using an aircraft window specific cleaner or a plastic cleaner approved for cleaning acrylic windshields. When polishing the windshield or side windows never polish in a circular motion, this creates a halo affect when looking into the sun. Always use horizontal or vertical pattern. The engine and engine compartment The Rotax 912 maintenance manual recommends the use of a commercially available cold cleaning agent. Some citrus based products have been found to be suitable. However, always read the instructions for any product to be used, keeping in mind that it must be compatible with both the engine components and the airframe structures. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-3 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.6 Views, dimensions Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-4 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 Geometry Max. length 6604 mm 21 ft 8 in Max. height 2342 mm 7 ft 8 in Wing span 8594 mm 28 ft 2 in Areas Wing 9.98 m2 107.43 sq ft Stabilator 1.60 m2 17.20 sq ft Vertical tail 1.41 m2 15.16 sq ft Aspect ratios Wing 7,29 Stabilator 3,38 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-5 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.7 Construction Materials The airframe is made of high-quality composite materials which permit excellent aerodynamic characteristics to be achieved at an efficient structural mass. Due to the strict mass regulations for ultra-light aircraft, re- inforced carbon and aramide fiber materials predominate. Due to the complex nature of composite materials and the necessary knowledge in the lay-up of a specific structure, repair work on the composite airframe may only be undertaken by a qualified facility. For this reason, only general information about the materials used is given in this handbook. Should the aircraft structure be damaged, detailed information should be requested from the manufacturer. Carbon, aramide, glass fiber: various qualities Lange & Ritter, Gerlingen Resin and hardener: Larit L 285 Lange & Ritter, Gerlingen Core material: Rohacell, Airex various qualities Lange & Ritter, Gerlingen Screws and bolts: unless otherwise stated, class 8.8 zinc-plated or stainless steel, according to DIN standard Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-6 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.8 Equipment List Each aircraft is delivered with an initial equipment list as part of this handbook. A new equipment list must be compiled and added to aircraft logbook and to this manual when there is any change to the equipment. The owner of the aircraft is responsible for ensuring that the equipment list is current. The equipment list includes options which are not certified in all the countries in which the CTLS may be operated. It is the responsibility of the owner to ensure that national regulations are followed, for example with respect to the ballistic recovery system and the autopilot. The equipment list is a summary of the aircraft at the time of an annual inspection or weighing. It is mandatory to record the installation and/or removal of instruments in the aircraft logbook. . Note: Sample weight and balance sheet only; not valid for the actual aircraft. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-7 AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 1.9 Source to Purchase Parts Spare parts can be ordered directly with the airplane manufacturer: Flight Design GmbH Zum Tower 4 01917 Kamenz Germany Web: www.flightdesign.com e-mail: customer.care@flightdesign.com 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. Specific contact in USA: Flight Design USA P.O. Box 325 South Woodstock, CT. 06267 860-963-7272 Web: www.flightdesignUSA.com e-mail: airworthiness@flightdesignUSA.com 1.10 List of Disposable Replacement Parts Air filter Air filter C2039, Art. C9997770 Fuel filter Fuel Filter 5/16’’, Art C9997813G Oil filter Oil filter – according to Rotax maintenance manual Front & Main wheel Tyre 4.00-6 BfGoodrich 4PR PowerHoby Tyre 4-ply 4.00 - 6" /4 PR V-5501 TT (B11) Tyre 6PR Sava 4.00-6 6PR B11 Tube 3.50-6" not certified Tube 4.00-6 Pn TR13 Tube Sava, 3.5.00-6 38G11.5, 6 ply Tundra front wheel Tube 4.00-6 Pn TR13 or Tire 4.00-6 BfGoodrich 4PR PowerHoby Tundra main wheel Tyre 4-ply 6,00-6" Air TRAC (420x140) or Tyre 4-ply 6,00-6" Air TRAC Batteries Battery Powersafe SBS 8 or Battery Cyclon Brake Assemblies Master brake cylinder, Art C9997205L O-Ring set for master brake cylinder Brake pads for magnesium caliper, Art C9997214D Aeroshell fluid 41 MIL-H-5606 Brake Fluid Brake disk, Art C9997206M Caliper, Art C9997205K Sparkplugs Ignition plug - according to Rotax maintenance manual Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-8 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.11 Weight and Balance Information Maximum take off weight: 1320 lbs 600 kg Typical empty weight: 683 lbs 310 kg Typical useful load 622 lbs 290 kg Maximum weight per seat: 260 lbs 118kg Maximum baggage weight per side: 55 lbs 25 kg Maximum fuel load (34 gal) 205 lbs 93 kg The acceptable empty center of gravity range is 11.1 to 18.82 inches / 282-478 mm behind the leading edge of wing. Weighing: The airplane is to be put on a level space on three scales or one scale with leveling blocks. Make certain the plane is leveled using a bubble level put onto the tunnel between the seats. The location of wheels is marked on the ground by a plumb. The loaded center of gravity is located behind the leading edge of wing. Spanwise location of the datum is not important, as the wings are rectangular and un-tapered. Important: While determining the loaded center of gravity the aircraft must be leveled. A Weight and Balance Sheet supplied with each plane. The example of it is shown below. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-9 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 Note: Sample weight and balance sheet only; not valid for the actual aircraft. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-10 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.12 Tire Inflation Pressure Main wheels: 29 PSI / 2 bar Nose wheel: 29 PSI / 2 bar 1.13 Approved Fluids and Capacities Quality automotive motor oil as specified by the engine manufacturer has to be used. The engine is not approved for aircraft motor oil. Allowed viscosities are listed in Chapter 10 of the Engine Operator’s Manual for all versions of ROTAX 912. Do not use oil additives. Oil capacity: 6,4 liq pt – min. 4,2 liq pt 3 l – min. 2 l Oil consumption: max. 0.13 liq pt/h 0,06 l/h The fuel valve is purely on / off and has to be in the appropriate maximum position. This engine does not have a mixture valve or require leaning. Fuel content: (2 wing fuel tanks for 65 l) 34 U.S. gal 130 l Maximum fuel available: 33 U.S. gal 124 l Fuel consumption: max 7 U.S. gal/h 27 l/h Fuel specification: Premium Automotive Unleaded that conform to ASTM D 4814 Minimum AKI 91 for Rotax 912ULS or AVGAS 100 LL. Cooling fluid: Cooling fluid in accordance with the Rotax Engine Operation Manual has to be selected. Attention: different coolants cannot be mixed! If in doubt, drain the complete coolant content and replace completely with new coolant of one type. Warning: Due to its high lead content AVGAS has a detrimental effect on valve seating and causes greater deposition in the combustion chamber. It should thus only be used if fuel vapor or octane problems arise or if MOGAS is not available. Warning: When using AVGAS particular attention must be paid to type of oil used. For details refer to the valid version of the ROTAX engine manual. Warning: Engine relevant data given here is not complete. For complete information refer to the current version of the relevant engine manual from the Rotax company. Braking fluid: Aeroshell Fluid 41 MIL-H-5606 Brake Fluid Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-11 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.14 Recommended Fastener Torque Values and Bolts Installation ATTENTION! All bolts has to be mounted up to down, inside to outside or front to aft, unless explicitly stated otherwise. Bolt Bolt M5 DIN 912-8.8 Bolt M6 DIN 912-8.8 Bolt M8 DIN 912-8.8 Bolt M5 DIN 7991-8.8 (countersunk) Bolt M6 DIN 7991-8.8 (countersunk) Bolt M5 DIN 931 -8.8 Bolt M6 DIN 931 -8.8 Bolt M8 DIN 931 -8.8 Bolt M5 DIN 933 – 8.8 Bolt M6 DIN 933 – 8.8 Bolt M8 DIN 933 – 8.8 Nut Nut M5 DIN 985-8,8 Nut M6 DIN 985-8,8 Nut M8 DIN 985-8,8 Nut M5 DIN 985-8,8 Nut M6 DIN 985- 8,8 Recommended Torques for class 8.8 (ISO 898) fasteners 52 lb-in 5.9 N*m 89 lb-in 10 N*m 222 lb-in 25 N*m 52 lb-in 5.9 N*m 89 lb-in 10 N*m For areas with thick bonding seams (cotton + cab-o-sil + resin + hardener) 49 lb-in 5.5 N*m 80 lb-in 9 N*m 200 lb-in 22.5 N*m 40 lb-in 4.5 N*m 71 lb-in 8 N*m Parts of PVC 49 lb-in 5.5 N*m 80 lb-in 9 N*m 200 lb-in 22.5 N*m 49 lb-in 5.5 N*m 80 lb-in 9 N*m Carbon fabric composite packages assemblies 49 lb-in 5.5 N*m 80 lb-in 9 N*m 200 lb-in 22.5 N*m 49 lb-in 5.5 N*m 80 lb-in 9 N*m Plywood bonded into composite 40 lb-in 4.5 N*m 71 lb-in 8 N*m 160 lb-in 18 N*m 31 lb-in 3.5 N*m 62 lb-in 7 N*m Glass fiber composite packages 49 lb-in 5.5 N*m 80 lb-in 9 N*m 200 lb-in 22.5 N*m 49 lb-in 5.5 N*m 80 lb-in 9 N*m Metal parts assemblies (steel, stainless steel, aluminum alloys) 53 lb-in 6 N*m 89 lb-in 10 N*m 222 lb-in 25 N*m 53 lb-in 6 N*m 89 lb-in 10 N*m As long as not stated otherwise within this manual, for bolts using standrad nuts, or botls otherwise unsecured, Loctite must be applied. Middle strength loctite is to be used when bolts are mounted to plastic components. In all cases, used self locking nuts (with plastic locking ring) must be exchanged after new ones at any time. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-12 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 1.15 General Safety Information ATTENTION! During all service and repair work beware of activating the Ballistic Parachute system rocket! While running the engine on the ground, keep away from the propeller. An accidental engine start is very dangerous! Ensure that the Ignition Switch C9997199 and main switches [Pushbutton Thermal, 30A C9997190B, Pushbutton Thermal 109S, 25A C9997190 (Fig. 1)] are turned off! Fig. 1 Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-13 AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 1.16 Instructions for Reporting Service Difficulties Issues observed during maintenance that have the possibility to affect Safety of Flight must be reported to Flight Design, providing at least the following information: Owner (or contact person) Inspector Aircraft Make/Model and S/N Engine Make/Model and S/N Date of inspection TT Airframe TT Engine Description of the un-airworthy items found Submit reports by email, fax or letter to the fopllowing contact, preferrably using the form Service Difficulty Report (Appendix III): Flight Design GmbH Zum Tower 4 01917 Kamenz Germany Web: www.flightdesign.com e-mail: customer.care@flightdesign.com … or to 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. Specific contact in USA: Flight Design USA P.O. Box 325 South Woodstock, CT. 06267 860-963-7272 Web: www.flightdesignUSA.com e-mail: airworthiness@flightdesignUSA.com Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 1-14 AF 0480 0001 Revision No. 8 Date: 27-Nov-2014 < empty page > Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 2-1 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 2 Minimum Levels of Certification: 2.1 General For each task listed in the maintenance manual, a minimum level of certification is specified. For example: Owner/Pilot, RLSA-M and A&P. Where a minimum level of certification is specified, the implication is that an individual who holds a Light Sport Repairman certificate with a maintenance rating (listed here as a RLSA-M) may perform any task with the minimum level of competency listed as “Owner/Pilot”, and an A&P may perform any task where the minimum level of competency is listed as Owner/Pilot, or RLSA-M. Minimum levels of certification do not preclude the need for additional or task specific training. As a general rule, additional or task specific training is required for heavy maintenance tasks and is required on a case by case basis for line maintenance tasks. The requirement for additional or task specific training will be listed where applicable throughout the manual. Note: Some tasks may require additional or task specific training for an RLSA-M but not for the holder of an A&P certificate. 2.2 Levels of certification Levels of certification used in this manual are: Owner/Pilot: The owner of an aircraft who holds a pilot certificate but who has not receivedany specific authorized training. Note: FAA regulations authorize SLSA aircraft owners who hold at least a sport pilot certificate to perform maintenance as outlined in 14CFRPart43. RLSA-M: The holder of a LSA Repairman certificate with a maintenance rating. This is generally considered the minimum level of certification to perform line maintenance of LSA. A&P: An Airframe and Powerplant mechanic as defined by 14 CFR Part 65 in the U.S. or equivalent certification in other countries. For and questions or comments regarding maintenance procedures or minimum levels of certification, email Flight Design USA at airworthiness@fiightdesignusa.com . Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 2-2 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 2.3 Required certification level for maintenance procedures In accordance with applicable standards, the requirements for minimum levels of certification and task specific training are listed through out this manual. The following table provides an overview on the allocation of certification levels through out this manual. Chapter Procedure Minimum Level of Certification Owner/Pilot RLSA-M FD Training 4 Structures 4.1 Wing 4.1.2 Wing installation and removal  + 4.2 Nose Landing Gear 4.2.1.4 Nose Landing Gear Inspections  4.2.1.5 Nose Gear Removal  4.2.1.6 Nose Wheel  4.2.2 Main Landing Gear 4.2.2.4 Inspection  4.2.2.5 Main Wheel Fairing Removal  4.2.2.6 Main Wheel Removal  4.2.2.7 Main Strut Fairing Removal  4.2.2.8 Main Gear Struts Removal  + 4.2.2.9 Wheel Inspection and Maintenance  4.2.3 Brake System 4.2.3.3 Inspection  4.2.3.4 Filling Brake System with Fluid  4.2.3.5 Brake Pads Replacement  4.3 Flight Controls 4.3.1 Aileron 4.3.1.5 Inspection  4.3.1.6 Aileron Installation  + 4.3.1.7 Aileron Adjustment  + 4.3.2 Flaps 4.3.2.4 Inspection  4.3.2.5 Flap Installation  + 4.3.2.6 Flap Adjustment  + 4.3.2.7 Inspection of Flap Controller Microswitches  4.3.3 Rudder 4.3.3.3 Rudder Installation  4.3.3.4 Rudder Deflection Adjustment  + 4.3.4 Stabilator 4.3.4.4 Stabilator Installation  4.3.4.5 Stabilator Adjustment  + 4.3.4.6 Balancing of Stabilator Balancer  + 4.4 Structural Repair  + 4.5 Painting and Coating  + Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 2-3 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 Chapter Procedure Minimum Level of Certification 5 Engine 5.1 Engine Systems and Accessories case dependent 5.2 Rotax 912 Engine case dependent 5. 3 Carb Heat Control  6 Fuel System 6.4 Fuel System Inspection  6.5 Fuel Flow Check  + 6.6 Intake Filter Inspection  6.7 Fuel Filter Inspection  6.8 Gascolator Inspection  7 Propeller  8 Utility Systems 8.3 Inspection of Cabin Heat System  9 Instruments and Avionics 9.3 Instrument maintenance  9.4 Inspection of Pitot and Static System  10 Electrical System 10.3.1 Inspection  10.4 Battery Replacement  Where listed, “FD Training” indicates the requirement for Flight Design task specific training. Flight Design task specific training may consist of one, or a combination of the following: 1. An approved Flight Design maintenance training course, 2. Individual training provided by a Flight Design representative 3. Training via multi-media or electronic means. Note: For certificated persons such as an A&P, RLSA-M or persons working under the auspices of a Repair Station, prior experience will be considered when determining the training required. Important: Participation in training described in this manual shall not be construed as an implicit authorization by Flight Design to perform inspections or repairs beyond the limitations set forth in the applicable regulations of the governing aviation authority. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 2-4 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 < empty page > Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-1 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3 Aircraft Inspections The following pages contain checklists suitable for performing periodic aircraft inspections of the Flight Design CTLS. Note: The ROTAX 912 Maintenance Manual contains a periodic maintenance schedule for the 912 ULS engine. Engine checks at 100hour according to Rotax maintenance manual are highly recommended to be conducted on time out of safety reasons. Condition inspection checklist Owner’s Name: ________________________________________________ Inspector’s Name: ______________________________________________ Aircraft Make/Model: Flight Design CT / _________________. S/N: __________________. Engine Make/Model: ____________________________________. S/N: __________________. Date of Inspection: _____________ TT Airframe: __________________ TT Engine: ___________________ Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-2 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.1 Aircraft Records CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Aircraft logbooks. Determine total times, times since overhaul and times since last required or recommended maintenance checks and record on Inspection Coversheet.   RLSA-M Safety Directives (SD’s), Airworthiness Directives (AD’s) and Service Bulletins. Check SD’s, AD’s, and Service Bulletins which may need to be complied within the inspection.  RLSA-M Aircraft records. Check for presence and condition of aircraft federal registration form and airworthiness certificate.  RLSA-M Aircraft Operating Instructions (AOI). Check AOI revision number to be actual, Equipment List and latest Weight and Balance information.  RLSA-M Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-3 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.2 Run-up Run-up shall be done prior to any inspection. Run-up shall at least take long enough to bring all temperatures to levels acceptable for takeoff. CT Inspection and/or Maintenance Checklist Inspection: 1. 100hour 2. Annual ELT battery due: Altimeter / Transponder test due: Systems Pre-inspection Post-inspection Starter   Oil pressure psi psi Brakes   Instruments & avionics   Ignition ground test (See Chapter 10.3.5 of the Operator’s Manual for all versions of ROTAX 912)   Oil temperature F F WARNING: Ensure cylinder heads temperature (CHT) and oil temperature are within limits. Cabin heat   Oil pressure psi psi Idle RPM RPM RPM WARNING: Allow engine to cool to 300F (CHT) before shutdown. All exterior lights are off   Check for fuel odors in cabin   Check for fuel stains on floor   Check fuel valve off function   Notes: Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-4 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.3 Post-Run-up CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Engine cowling. Remove engine cowling.   RLSA-M Engine oil. Check the level of oil and follow the Operator’s Manual for all versions of ROTAX 912.   RLSA-M Exterior lights. Check operation of landing lights (if applicable), position lights, and strobe lights.   RLSA-M Interior lights. Check operation of interior lights (if applicable).   RLSA-M Flight controls. Check for smooth operation of all flight controls with flaps in retracted and extended positions. Leave flaps in the full up position when checks are completed.   RLSA-M Door apertures protection. Check protection for wearing and flanges for cracks.  Owner/Pilot Rudder neutral position system. Check operation.  RLSA-M Environmental Control System (ECS). Check operation of the door window vents.  Owner/Pilot Trim tab. Check trim tab position and indicator reading.  RLSA-M Brake System. Check wheel chocks and disks for wearing. Check the level of fluid in the hydraulic system. Inspect the protection PVC hoses in the places where brake lines go through the fuselage skin (see p. 4-32 - Chapter 4.2.3.5.2).   Owner/Pilot Battery. Fully charge and clean up the battery surface and cables. Check the battery for reliable contact with the cables.   Owner/Pilot Fairings, access panels, seats, carpets, covers, and spinner. Remove for inspection to ensure access. Check for missing or unscrewed bolts and nuts.   RLSA-M Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-5 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.4 Propulsion System CT Inspection and/or Required Maintenance Checklist 100 hour Annual Minimum Level of Certification Cleaning. Clean the engine as required in the Maintenance Manual for ROTAX Engine Type 912 Series.  *  Owner/Pilot Engine. Inspect all systems as required in the Maintenance Manual for ROTAX Engine Type 912 Series.  *  Owner/Pilot Induction system. Check connection of manifolds between Air filter box and carburetors. Check the carburetor heater choke in the Air filter box for operating. Check for fuel leakage nearby carburetors.   Owner/Pilot Induction air filter. Inspect for cleanliness and condition of sealing surfaces. Replace filter, if damaged.   Owner/Pilot Cabin Heater. Check clamps and heater attachments. Check the manifold for holes and attachments.  RLSA-M Exhaust system. Inspect entire system for cracks, and security.  RLSA-M Fuel sight gages. Inspect for security and presence of fuel leakage. Check operation of throttle and choke controls. Ensure levers hit stops before cables reach end of travel.   RLSA-M Fuel manifold valve and distribution lines. Inspect for evidence of fuel leakage. Inspect distribution lines for cracks, and signs of leakage.   Owner/Pilot Gascolator. Open gascolator, remove filterand check for cleanliness. Clean filter and re-install.   Owner/Pilot Fuel lines. Inspect all flexible fuel hoses for routing, chafing, security, and signs of leakage.   RLSA-M Fire Protection Hoses. Icheck for condition and integrity on all fuel and oil lines inside the engine compartment.   RLSA-M Fuel Flow Rate. Check fuel flow rate to be correct every 100 hrs. Compare value with previous value. In case of significant variations or too little flow refer to the relevant section of the Maintenance Manual.   RLSA-M Spinner. Inspect for cracks, security to propeller. Clean inside of spinner.  Owner/Pilot Propeller hub. Inspect for cracks, corrosion. Re-torque all mounting nuts, if loss of torque is suspected on any nut.  RLSA-M Propeller blades. Inspect for play, dents, nicks, cracks, corrosion, pitting, and leading edge erosion.   Owner/Pilot Engine cowlings. Inspect for cracks, chafing, heat damage, and delamination, evidence of exhaust leakage, condition of fastening system, and condition of paint.   Owner/Pilot Landing and taxi lights. Inspect for cracks, security of mounting, and cleanliness and condition of lens cover. Operate landing lights in a dark area and ensure that lights are properly aimed. If lights are not properly aimed, adjust as required.   Owner/Pilot Firewall. Inspect for cracks, buckling, and other signs of damage. Inspect all items attached to firewall for security.   Owner/Pilot * - Engine checks at 100hour according to Rotax maintenance manual are highly recommended to be conducted on time out of safety reasons. Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-6 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 CT Inspection and/or Required Maintenance Checklist 100 hour Annual Minimum Level of Certification Engine mount. Lift up the nose landing gear off of the ground and inspect for cracks, corrosion, loose hardware, chafing by cables, wires, hoses, etc., and make sure that any flexing item is secured to the engine mount.   RLSA-M Engine isolators. Inspect for general condition and signs of loose bolts.   Owner/Pilot Battery attachment. Inspect for security of mounting and condition. Ensure vent holes are clear.   Owner/Pilot Foreign objects. Check engine compartment for foreign objects.   Owner/Pilot 3.5 Fuselage CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Skin surface. Inspect for obvious latent signs of damage, including cracks, holes, buckling. Check drain holes for obstructions. Check condition of paint and cleanliness.   Owner/Pilot Placards. Inspect for presence and condition.   Owner/Pilot Windows. Inspect for cleanliness, condition, and bonding. Check door windows for scratches, cracks. Check door vents operating.   Owner/Pilot Cabin doors. Inspect for operating and fit. Inspect skin, hinges, gas struts, latching mechanisms, and door seals. Lubricate hinges and all moving parts.  RLSA-M Baggage door. Inspect for operating and fit. Inspect door skin, seal, hinge, and latching mechanism. Lubricate all moving parts.  RLSA-M Static Port. Check static port for evidence of obstructions. Caution: Do not apply compressed air to the system, since this will result in damage to the static air flight instruments   RLSA-M Antennas. Inspect for security and condition.  RLSA-M Aircraft identification tag. Inspect for security and legibility.  RLSA-M Fin. Inspect fin for visible damage and evidence of latent damage. Inspect hinge attach points for security and condition.   Owner/Pilot Underfin. Inspect underfin for visible damage and evidence of latent damage. Inspect attach points for security and condition.   Owner/Pilot Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-7 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.6 Wings CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Wing Attachment Area. Inspect wing spar and main bolt bushings for cracks and debonding. Check visible attaching hardware for loss of torque. Inspect aileron bellcranks for cracks and corrosion. Check root rib pins for debonding and cracks, and the forward one for fuel leak. Check each 600 hrs or at the next 100 hrs inspection after 2 years, whichever occurs first.   RLSA-M Fuel Tanks. Check wing leading edge for cracks and for fuel leak. Inspect outer skin in tank area for signs of fuel leakage. Inspect within visible area of the fuel tank for foreign objects. Inspect the fuel tanks vents - NACA inlets on the outer side of each of the upper winglets, for obstruction, connections for leaks. Check fuel flow through the gascolator. For more detailed instruction see Chapter 6, Fuel System.   Owner/Pilot Fuel filler and caps. Inspect for proper locking, condition of o-ring and filler, and presence and legibility of placards.   Owner/Pilot Fuel Intake Filter. Check intake filter every 1000 hrs or after negative fuel flow test.   Owner/Pilot Fuel contamination test. Take fuel samples from both wings and fuel strainer. Inspect for contamination and proper grade of fuel.   RLSA-M Wing skins. Inspect for obvious signs of damage, including cracks, holes, and buckling. Check condition of paint and placards. Check drain holes for obstructions.   Owner/Pilot Aileron and flap brackets. Inspect for security of attachment to wing. Inspect bearing for condition and play as required in Chapter 3.4.1.6.2 Aileron; 3.4.2.6.2 Flaps.   RLSA-M Ailerons. Inspect for damage, looseness, or play in attach bearings, and condition of rod end attachment. Check security of static balance weights. Check for obstruction of drain holes. Lubricate the rod tip bearing as required in Chapter 3.4.1.6.2 Aileron; 3.4.2.6.2 Flaps.   RLSA-M Flaps. Inspect skins for condition and signs of debonding. Check hinges for play and attachment to wing and flap. Check flap rod and rod tips for condition, and lubricate.   RLSA-M Flap actuator. Clean and run flaps up and down to check for smooth operation.   Owner/Pilot Flap deflection. Ensure that flaps extend equally on each side of the airplane in the takeoff, cruise and landing configurations. Measure the down deflection on each side using neutral ailerons as a reference point. The difference in static deflection should not be greater than 1/8‘’ / 3 mm. Inspect stop switches for operating. See detailed instructions in Chapter 4.3.2 Flaps.   RLSA-M Wing interior. Inspect wing spar through outer access panel and access holes along the trailing edge for signs of cracks or debonding. Inspect visible bonded areas of ribs and other structures.  RLSA-M Flight controls. Inspect all push-pull rods, rod end bearings and bellcranks for condition, play, security of attachment and lubricate. Ensure locking is proper where applicable.   RLSA-M Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-8 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Pitot port. Inspect for obstruction of Pitot, signs of damage, which may affect proper airflow. Remove the Pitot port before attempting to clear any obstructions, making sure the port is not damaged in any way. Test for proper operation after reinstallation.   RLSA-M 3.7 Empennage CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Rudder. Inspect for signs of damage, looseness, or play in bearings, and condition of hinge attachments and rudder cable attachments. Check security of static balance weight. Check for obstruction of drain holes. Lubricate hinges and cable-attach points. Ensure rudder stops on the nose gear steering rods make full contact with left and right rudder stops on the engine mount. Verify rudder angles of deflection as required in Chapter 4.3.3.6, Rudder Deflection Adjustment.  RLSA-M Stabilator with trim tab. Inspect for visible damage and evidence of latent damage. Inspect looseness or play in bearings. Check security of static balance weights. Check for obstruction of drain holes. Lubricate hinges. Ensure stabilator forward and aft stops make full contact with stop plate. Verify stabilator angles of deflection as required in Chapter 4.3.4.7, Stabilator Rigging.  RLSA-M Flight controls. Inspect all push-pull rods, push-pull cable, rudder and trim-tab control cables, rod end bearings and bellcranks for condition, play, security of attachment and lubricate. Ensure locking is proper where applicable.  RLSA-M Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-9 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.8 Landing Gear CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Visual inspection. Inspect from top to bottom for scratches, cracks, corrosion, signs of overstress and side-loading. Visually inspect the struts for straightness. See Chapters 4.2.1.6.1 and 4.2.2.6.1.   Owner/Pilot Wheels. Inspect for cracks and corrosion. Check all hardware for signs of loss of torque. Inspect tires for splitting, flat spots, wear, and dry-rotting. Check tire pressure (2 bar /29 PSI), and service as necessary. See Chapters 4.2.1.6.1 and 4.2.2.6.2.   Owner/Pilot Fairings. Inspect for condition, scratches, cracks, and signs of overstress. Clean interior. See Chapter 4.2.1.5; Chapter 4.2.2.5 and Chapter 4.2.2.7.   Owner/Pilot Wheel bearings. Inspect for damage, wear, and corrosion. Check bearing for play, binding and bearing protection plate for condition. Replace bearings if necessary. See Chapter 4.2.1.6.   RLSA-M Nose landing gear. Lift up the nose gear and check rotation of the nose gear within operating limits for binding. Check the steering lever and the strut for play. See Chapter 4.2.1.6.4.  RLSA-M Shock absorber. Inspect for binding and unusual noises while operating. See Chapter 4.2.1.7.5.  RLSA-M Hydraulic brake lines. Inspect brake lines that are tie wrapped to the main gear strut. Check for security and evidence of chafing. Check for leaks (hydraulic fluid stains).   RLSA-M Brake calipers, brake pads and brake discs. Clean and inspect for condition, fluid leakage, for cracks and corrosion, security of components. Inspect brake discs for pitting and signs of overheating. Inspect all hardware for signs of loss of torque. Do not lubricate. Ensure the brake discs have a little amount of free motion along the wheel axle. See Chapter 4.2.3.   RLSA-M Brake fluid reservoir. Inspect for condition, security, and fluid level. Service, if necessary.   Owner/Pilot Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-10 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.9 Cabin and Baggage Compartment CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Fire extinguisher. Remove fire extinguisher (if applicable) and check that expiry date is not exceeded. Replace if necessary.  RLSA-M Upholstery. Inspect for general condition, attachment, and cleanliness.  Owner/Pilot Safety belts. Inspect belts for wear, cuts, and broken stitching. Check all buckles for proper locking and release. Check belt attachments to structure.  RLSA-M Flight controls. Inspect for dents, nicks and scratches in push-pull rods, play in rod end, security of rudder cable guide tubes to fuselage. Lubricate rod end bearings.  RLSA-M Seats. Inspect seat structure for general condition, cracks, and corrosion. Check seat controls for locking. Inspect cushions and upholstery for condition.  RLSA-M Seat guides and stops. Inspect for cracks, wear of latching holes and guides, and security of guides and stops.  RLSA-M Avionics. Check control knobs for operating. Check security of indicators, radios, GPS display (if applicable), controls on side and central panels, and markings legibility. Magnetic tools must not be used during this procedure.  Owner/Pilot Instruments. Check security of instruments and markings legibility. Magnetic tools must not be used during this procedure.  Owner/Pilot Placards. Inspect for presence and condition of all required interior placards.  Owner/Pilot Instrument panels. Inspect for general condition, security of attachment, and cleanliness. Magnetic tools must not be used during this procedure.  Owner/Pilot Magnetic compass. Inspect for security and oil leakage. Inspect compass correction card for presence and legibility of all headings. Magnetic tools must not be used during this procedure.  RLSA-M Fuel valve. Inspect for operating and signs of fuel leakage.   RLSA-M Fuel Filter. Change fuel filter behind lower instrument panel at least every 200 hrs.   RLSA-M ECS controls. Check cabin and carburetor heating, heating ducts and side window vents for proper operation.  Owner/Pilot Instrument board inside and panels’ backside. Remove all instrument panels and inspect all lines, wires, control cables, hoses, instruments, and so on, for chafing, any interference, and loose or stressed connections. Inspect firewall structure for cracks, debonding, and general condition.  RLSA-M Reinstall instrument panels. Check security of attachment and condition.  Owner/Pilot Rudder pedals. Inspect for security, cracks, and play. Lubricate pedals PVC supports.  RLSA-M Parking brake valve. Inspect for security of mounting and signs of leakage.  RLSA-M Main Bulkhead. Inspect for cracks, dents, and debonding from the fuselage.  RLSA-M Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-11 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Main landing gear attachment boxes. Inspect for cracks, debonding and security of hardware.  RLSA-M Floor (pyramid), tunnel, fuselage root ribs, spar box, A-struts. Inspect for cracks, holes, debonding and general condition.  RLSA-M Flight controls (forward fuselage through baggage compartment). Inspect for nicks, scratches, and dents in push-pull rods, play in rod end and attachment of rudder cable guide tubes to fuselage. Lubricate rod end bearings.  RLSA-M Baggage compartment doors. Inspect for cracks, holes, and security.   Owner/Pilot ELT. Remove from bracket and remove battery cover. Inspect for battery corrosion and any obvious internal or external damage to housing. Verify replacement date on battery matches date on housing placard. Reinstall battery cover. Inspect as required in the ELT Maintenance. Record battery replacement due date: ________________   RLSA-M ELT installation. Inspect ELT wiring and antenna cable for security, routing, and chafing. Check connectors for security of pins and proper connection. Inspect ELT bracket for cracks and security. Replace bracket if any cracks are found.  RLSA-M Tail beam (from the baggage compartment towards tail) and empennage interior structure. Inspect for cracks, debonding, or other signs of damage. Make sure that all drain holes are clear of obstructions. Check rudder control cable guides and push-pull cable guides for debonding.  RLSA-M Access panels. Inspect for condition. Check fasteners for condition.  Owner/Pilot Maintenance and Inspection Procedures Manual Type: CT Series: CTLS LSA Page: 3-12 AF 0480 0001 Revision No. 3 Date: 14 Sep 2008 3.10 Inspection Completion CT Inspection and/or Required Maintenance Checklist 100hour Annual Minimum Level of Certification Fuselage and wings. Make sure aircraft is free of any tools, parts, and debris, and reinstall all access panels, fairings, seats, and so on, removed for the inspection.   Owner/Pilot Engine. Verify that there is oil in the oil tank, cooling liquid in the expansion tank and coolant level in overflow bottle take place between min. and max. marks as required by the Operator’s Manual for all versions of ROTAX 912, and engine compartment is free of tools, rags, and debris.   Owner/Pilot Engine. Run engine for no more than two minutes at 1400 to 1800. After shutdown, check for leaks at oil filter, and any other components removed during this inspection. Install cowlings, if no leaks are noted.   Owner/Pilot Aircraft. Operate engine at 2000 to 2500 RPM to warm it up. Operate all aircraft systems to verify proper operation. As engine warms, operate engine systems at appropriate engine speeds and complete all checks listed on Inspection Coversheet.   Owner/Pilot Aircraft records. Complete entries in logbooks, AD and SD compliance lists, and any other required records.   Owner/Pilot