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FLIGHT DESIGN CTLS Series, Maintenance And Inspection Procedures Manual

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Maintenance and Inspection Procedures Manual 

 

Type: 

CT

 Series: 

CTLS 

LSA

 

Page: ii 

 

AF 04800001 

Revision No. 4 

Date:    02 Jan 2009 

 

REVISION STATUS  

 

Rev Pages 

Date 

Chapter 

completed 

1 

All 

Jan 10, 2008 

All 

Vasyl Sys 

- 

System of pages numbering changed 

 

 

- 

Formatting (page breaks) partially changed 

All 

“or higher grade of certificate” added to 

 

“Repairman, Light Sport Aircraft-Maintenance 
(RLSA-M).” 

1-5 

1.6 Equipment List updated 

1-10–1-11 1.13 

changed 

1-12 

1.15 “Owner’s operational” changed to “Service” 

8-1 8 

changed 

8-2 8.5.2 

changed 

8-2 8.5.3 

changed 

8-3 – 8-4 

8.5.10 – 8.5.16 added 

8-5 8.6 

changed 

2 

1 

Apr 01, 2008 

App. 1 updated 

Vasyl Sys 

1-1 

1 Updated with Warning 

1-2 1.3 

Warning 

deleted 

1-8 

1.9 Operating speeds and limits updated 

2-11–2-12 

2.9 updated with “Lubricate rod end bearings” 

3-1 

3 page numbers corrected in the table 

3-32–3-40 3.3.2 

updated 

5-2 5.1 

updated 

8-3 

8.5.9 C9997199F Switch panel EK 10228 deleted
8.5.10 Garmin SL30 added 
8.5.11 changed 

8-4 

8.5.13 changed 

All 

Number of document changed 

Vasyl Sys 

1 

App. I changed to App. V 

17 

App. I changed to App. V 

1-1 1 

updated 

1-1 

1.2 added contact 

1-6 

1.6 text added  

1-9 

1.9 “Engine specification” deleted 

1-9 

1.10 “Minimum single pilot weight” deleted  

3-10 3.1.2.6 

changed 

8-3 

8.5.6 Vertical Speed Indicator (Variometer) 
deleted  

9-1 

9. deleted incorrect drawing number  

11-1 11.1 

updated 

2-4 

2.3 – 2.10 updated 

3-11-3-21 

Sep 14, 2008 

3.2-3.2.1.9 “Stabilizer” moved to 3.4.4. 

Vlada Luzhnykh

3 

3-1 – 10-5 

 

Allocation of Level of Maintenance and Level of 
Certification detailed and adapted. Requirements 
for Flight Design Training reviewed. Linguistic  
clarifying corrections included throughout the 
whole procedures. 

O. Reinhardt 
 

1-1 

Address of Flight Design is changed 

4 

A

І

V-1-A

І

V-14 

02 Jan 2009 

Added Appendix IV MATCO Brake System 

S. Pilipenko 

Summary of Contents for CTLS Series

Page 1: ...tenance and Inspection Procedures Manual THIS DOCUMENT AND THE TECHNICAL DATA HEREON DISCLOSED ARE PROPRIETARY TO FLIGHT DESIGN AND SHALL NOT BE USED RELEASED OR DISCLOSED IN WHOLE OR IN PART WITHOUT EXPRESS WRITTEN PERMISSION FROM FLIGHT DESIGN ...

Page 2: ... corrected in the table 3 32 3 40 3 3 2 updated 5 2 5 1 updated 8 3 8 5 9 C9997199F Switch panel EK 10228 deleted 8 5 10 Garmin SL30 added 8 5 11 changed 8 4 8 5 13 changed All Number of document changed Vasyl Sys 1 App I changed to App V 17 App I changed to App V 1 1 1 updated 1 1 1 2 added contact 1 6 1 6 text added 1 9 1 9 Engine specification deleted 1 9 1 10 Minimum single pilot weight delete...

Page 3: ... 4 73 3 10 3 3 2 1 3 4 30 3 4 74 3 10 4 3 2 2 3 4 31 3 4 75 3 10 10 5 3 2 2 3 3 4 32 3 4 76 3 AI 1 3 3 1 3 4 33 3 4 77 3 AI 2 3 3 2 3 4 34 3 4 78 3 App I AI 3 3 3 3 3 4 35 3 4 79 3 AII 1 3 3 4 3 4 36 3 4 80 3 App II AII 2 3 3 5 3 4 37 3 4 81 3 App III AIII 1 3 3 6 3 4 38 3 4 82 3 App IV AIV 1 AIV 14 4 3 7 3 4 39 3 4 83 3 3 8 3 4 40 3 4 84 3 3 9 3 4 41 3 4 85 3 3 10 3 4 42 3 4 cont 4 86 3 3 11 3 4 ...

Page 4: ...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 P...

Page 5: ...ification 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...

Page 6: ...e of Maintenance 4 49 4 3 2 4 2 Minimum Level of Certification 4 49 4 3 2 4 3 Bracket Inspection 4 49 4 3 2 4 4 Wing bracket bearings inspection 4 50 4 3 2 4 5 Rods Bellcranks inspection 4 51 4 3 2 5 Flap Installation 4 51 4 3 2 5 1 Type of Maintenance 4 51 4 3 2 5 2 Minimum Level of Certification 4 51 4 3 2 5 3 Procedure 4 51 4 3 2 6 Flap Adjustment 4 53 4 3 2 6 1 Type of Maintenance 4 53 4 3 2 6...

Page 7: ...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 Verifica...

Page 8: ... 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 inst...

Page 9: ...pe CT Series CTLS LSA Page ix AF 04800001 Revision No 4 Date 02 Jan 2009 Appendix I Template for Trim Tab Deflection Angles Measurement 1 Appendix II Adjustment report 1 Appendix III Service Difficulty Report Form 1 Appendix IV MATCO Brake System 1 ...

Page 10: ...ade 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 certificat...

Page 11: ...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 sandwi...

Page 12: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page 1 3 AF 04800001 Revision No 3 Date 14 Sep 2008 1 4 Views dimensions ...

Page 13: ...4 AF 04800001 Revision No 3 Date 14 Sep 2008 Geometry Max length 6604 mm 21 ft 8 in Max height 2342 mm 7 ft 8 in Wing span 8594 mm 28 ft 2 in Areas Wing 9 98 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 ...

Page 14: ...te 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 quali...

Page 15: ...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 i...

Page 16: ... 6 BfGoodrich 4PR PowerHoby Tyre 4 ply 4 00 6 4 PR V 5501 TT B11 Tyre 6PR Sava 4 00 6 6PR B11 Tube 3 50 6 not certified Tube 4 00 6 Pn TR13 Tube Sava 3 5 00 6 38G11 5 6 ply Tundra front wheel Tube 4 00 6 Pn TR13 or Tire 4 00 6 BfGoodrich 4PR PowerHoby Tundra main wheel Tyre 4 ply 6 00 6 Air TRAC 420x140 or Tyre 4 ply 6 00 6 Air TRAC Batteries Battery Powersafe SBS 8 or Battery Cyclon Master brake ...

Page 17: ...o 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...

Page 18: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page 1 9 AF 04800001 Revision No 3 Date 14 Sep 2008 Note Sample weight and balance sheet only not valid for the actual aircraft ...

Page 19: ... 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 ne...

Page 20: ...otton 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 1...

Page 21: ...N 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 ...

Page 22: ...ness flightdesignusa com information as follows 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 or by writing Flight Design USA Woodstock Airport 91 Route 169 P O Box 325 South Woodstock CT 06267 USA e mail flightdesignusa rcn com www flightdesignusa com using Service Diffic...

Page 23: ...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 ho...

Page 24: ...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 ...

Page 25: ...tion 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 certificate...

Page 26: ...12 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 _...

Page 27: ... 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 Operati...

Page 28: ...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 ...

Page 29: ...ave 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...

Page 30: ...olator 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 va...

Page 31: ... 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 ...

Page 32: ...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 r...

Page 33: ...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 d...

Page 34: ...mage 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 wh...

Page 35: ...cedure 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 Magnet...

Page 36: ...r 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 securi...

Page 37: ...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 e...

Page 38: ...ttached to the ribs along the trailing edge The aileron control rod runs behind the spar Two fuel filler caps are on the upper wing surface An access panel is located on the lower skin of the wing and inspection and maintenance holes are along the trailing edge of the wing The upper and lower skins are made of epoxy carbon fiber and foam core The spar caps are of epoxy carbon fiber and the spar we...

Page 39: ...Wing Installation Note If installing a replacement wing or repaired wing that requires wing root contouring explicit Flight Design task specific training required To install the wings requires three persons Prior to installation set the aircraft on the parking brake and remove any obstacle within 16 ft area from the fuselage Lubricate all metal details with LITOL 24M before connecting the flap pin...

Page 40: ...Series CTLS LSA Page 4 3 AF 04800001 Revision No 3 Date 14 Sep 2008 Fig 3 4 Connect all fuselage to wing wiring e g connect the position and strobe lights socket and plug 1 Fig 4 Fig 4 5 Match the groove on the tip 1 with the flap pin 2 Fig 5 Fig 6 Fig 5 ...

Page 41: ...04800001 Revision No 3 Date 14 Sep 2008 Fig 6 6 Match the hole of the aft bushing KA1000101 on the fuselage with the pin on the wing root rib KA2010301 1 Fig 7 Fig 7 7 Match the hole in the forward bushing KA1000110 of the fuselage with the pin of the wing root rib KA2010301 1 Fig 8 ...

Page 42: ...A1000101 bushings on the fuselage Take care that the flap pin KA2040013 gets into the groove of the tip KA6030201 Fig 5 Note that the pins can be set properly into the bushings by moving of the wing back and forth Fig 9 and up and down Fig 10 Fig 9 Fig 10 9 Support the pre set wing until both wings are installed and fixed by the main bolts КА2000010 10 Repeat the procedure except item 2 for the le...

Page 43: ... the spar bushing of the right wing KA2010102 with the hole of the bushing of the left wing KA2010103 from the right side moving the wing up and down Fig 9 Fig 11 12 Push the main bolts fully in e g set the main bolt KA2000010 1 into the matched holes of the bushings KA2010102 and KA2010103 by moving the wing up and down Fig 11 and 12 Fig 12 ...

Page 44: ...e cap and bolt e g set the caps KA2000013 1 onto the main bolts KA2000010 and fix them by bolts М8x35 С9996078А Fig 14 Torque value for the main bolts is 200 lb in 22 5 Nm Fig 14 15 Match the holes in the tip SMC6 of the rod KA6020050R with holes of the right wing lever КА6020040R Fig 14 16 Fix the rod KA6020050R 1 in the lever KA6020040R 2 with the bolt М6x30 С9996259А 3 Use only new self locking...

Page 45: ...Type CT Series CTLS LSA Page 4 8 AF 04800001 Revision No 3 Date 14 Sep 2008 Fig 15 17 Fuel hose is attached to the connection 1 Fig 16 Fig 16 Warning After wing installation the fuel system must be checked as described in Section 6 of this manual ...

Page 46: ...aining the aircraft should be performed in a ventilated area with fire precautions taken The rest of the wing removal process goes in reverse to the wing installation process 4 1 2 7 Verification Required 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 secu...

Page 47: ...DIN 912 M6x60 8 8 1 pcs C9996334 Self locking nut DIN 985 M6 1 pcs C9996336 Self locking nut DIN 985 M8 2 pcs C9996338 Self locking nut DIN 985 M12 1 pcs C9997730F O ring Simrit72 NBR 872 28 0x5 2 pcs C9997730P O Ring 8x18x4 2 pcs Talcum AR CIATIM 201 GOST 6267 74 or Aeroshell Grease 6 SHELL Unirex S 2 Esso Eneryrease LCI LT 2 British Petroleum 4 2 1 3 General Due to lifting loads being hazardous ...

Page 48: ...ntion to welding seam areas Check for obvious damage to all visible parts each time the fairing is removed Fig 1 item 2 2 The engine mounts for damage dents cracks Fig 1 item 3 Pay specific attention to welding seam areas Check all visible surfaces before each flight inspect engine compartment visually each time the cowlings are removed 3 The firewall for damage dents cracks delaminating Fig 1 ite...

Page 49: ...he left and release Repeat 2 3 times to each side If operation is suspected wrong see sections 4 2 1 5 and 4 2 1 6 Make sure there is no play between the pin KA4010101 Pin and the slot in KA4010110 Rotating body Replace the pin KA4010101 Pin if necessary see Chapter 4 2 1 7 Make sure there is no play between the KA4010001 Rocker Fig 2 and the KA4010110 Rotating body Replace if necessary see Chapte...

Page 50: ...LS LSA Page 4 13 AF 04800001 Revision No 3 Date 14 Sep 2008 4 2 1 5 Nose Gear Removal Replacement 4 2 1 5 1 Type of Maintenance Heavy 4 2 1 5 2 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher 4 2 1 5 3 Fork Removal Fig 2 ...

Page 51: ...be of correct circular shape and of constant thickness cracks dents nicks and wearing Check shape of the hole for the bolt C9996064 Check diameter of the hole for the bolt C9996064 that has to be not more than 0 237 inch 6 0 mm 0 197 inch 5 mm for replacement strut Check the bolt C9996064 Bolt DIN 912 M6x60 8 8 for integrity and thread condition Replace if necessary Apply a thin layer of grease Gr...

Page 52: ...out the hole in the fork tube by a 0 237 inch 6 0 mm drill e Set the bolt C9996064 Bolt DIN 912 M6x60 8 8 and secure it by a new nut C9996334 Self locking nut DIN 985 M6 regular having put a washer C9996565 Washer DIN 9021 6 4 mm VZ under the nut Use a 10x13 wrench and hex nut wrench 5 f Make sure that only new nuts C9996334 Self locking nut DIN 985 M6 regular are used and tightened 80 lb in 9 Nm ...

Page 53: ...grity of o rings C9997730F O ring Simrit72 NBR 872 28 0x5 0 and C9997730P O Ring 8x18x4 and replace if necessary 12 Replace the nut C9996336 Self locking nut DIN 985 M8 regular to a new one 13 Stack the polyurethane damper elements to the pin axis pos 4 as follows support pos 6 flat surface facing the first polyurethane element 6 polyurethane elements separated each by a washer pos 3 support pos 6...

Page 54: ...nts and cracks pay specific attention to the threaded part of it Replace if necessary 6 Inspect the wheel rims for dents and cracks Replace if necessary or suspected necessary 7 Inspect mounting holes in the wheel rims for bearing cracks and shape Replace if necessary or suspected necessary 8 Check bearings for condition 9 Inspect the tube for integrity Inspect the tire for foreign objects Inspect...

Page 55: ...lage exit supports the strut The fuselage exit is faired to an aerodynamically optimized form At the bottom of the landing gear strut there is a stub axle to which the main wheels and the brakes are attached The main wheels have removable fairings Fig 1 Due to lifting loads being hazardous two persons are required to remove install the main gear struts 4 2 2 1 Tools Required Wrench 10х13 2 pcs Wre...

Page 56: ... operation 4 Check the bulkhead and tunnel made of composites for damages dents cracks delamination at the areas of landing gear attachments 5 Inspect the main struts for bending damages dents cracks on the surface and especially at the mounting holes areas integrity and circularity of the mounting holes Check all visible surfaces before flight 6 Inspect annually for all stated above with removal ...

Page 57: ...ng the wheel fairing Remove the fairing Before installation make sure of integrity and security of the spacer KF32100036 Spacer The spacer must be installed with the middle strength Loctite 243 and tightened 49 lb in 5 5 Nm Installation is the reverse to removal NOTE The bolt C9996054B must be set with lock liquid of middle strength Loctite 243 and tighten 80 lb in 9 Nm the screws C9996162 Screw I...

Page 58: ...1 8 MSv and disconnect the line C9997205R 6x4 nylon tube Fig 3 pos 2 Prevent draining of brake liquid out of the hose by plugging it up Fig 3 4 2 2 6 4 Main Wheel Removal Refer to Fig 4 Fix bolt C9996088 Bolt DIN 912 M8x90 A4 70 with a hex nut wrench and unscrew axis KF32100036 Unscrew C9997207T Nut M20x1 5 Unscrew 4 Self locking nuts DIN 985 M6 regular C9996334 by a 10x13 wrench and wrench 6 Remo...

Page 59: ...self locking nuts only Note Torque moment for nuts Self locking nut DIN 985 M6 regular C9996334 9Nm Nut M20x1 5 C9997207T 70Nm Torque moment for bolts Bolt DIN 912 M8x90 A4 70 C9996088 9Nm Pin for brake disk C9997205I 9Nm For mounting KF32100043 KF32100037 C9996088 C9997205I use Bonding liquid middle strength Art No 3247 Mark all bolt nut connections with Enamel Red NC 132К Art No 09110 Install sp...

Page 60: ...craft Maintenance RLSA M or higher Fig 5 Take out the main wheel fairing KF32100010 KF32100011 Refer to section 4 2 2 7 Detach the wheel Refer to section 4 2 2 8 Detach the C9993230O Bowlus Maxi Gap Seal Tape 1 1 2 white from the fairing KF32100020 and fuselage Unscrew 2 screws M5x6 KF32100046 Detach the fairing Make installation in the reverse sequence Note Torque moment for screw M5x6 KF32100046...

Page 61: ...g required 4 2 2 8 3 Procedure 1 Take out the seats 2 Set an aircraft on a locating block 3 Detach a wheel refer to section 3 3 2 7 4 Detach the landing gear fairing KF 32100020 Fig 6 item 1 5 In order to detach the support KF32100044 Fig 7 item 4 unscrew 2 bolts KF32100042 M6 x 33 and 2 self locking nuts C9996334 Fig 7 items 1 2 Fig 6 6 Unscrew 2 bolts KF32100043 M6 x 85 and 2 self locking nuts C...

Page 62: ...К Art No 09110 Important Use only new M6 self locking nuts C9996334 4 2 2 9 Wheel Inspection and Maintenance 4 2 2 9 1 Type of Maintenance Line 4 2 2 9 2 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher 4 2 2 9 3 Procedure Fig 8 For main wheel inspection Fig 8 do the following 1 Unscrew the bolt KA4020503 Bolt by a 19x24 wrench 2 Unscrew C9997205I Pins for...

Page 63: ...in case of cracks height of tread less 0 04in 1 mm or inability to keep necessary pressure within 24h 10 Make sure that the spacer KA4020502 Distance bushing is of sufficient length to prevent bearing misalignment Replace if necessary 11 Assembly is a reverse of removal NOTE The bolt KA4020503 Bolt must be set on lock liquid of high strength Loctite 270 and C9997205I Pins on lock liquid of middle ...

Page 64: ...heel chocks each side of the wheels to prevent unintended motion of the aircraft All the connectors but the connectors A Fig 5 are to be tightened up to torque 80 lb in 9 Nm and secured by lock liquid of middle strength Loctite 243 The connector A Fig 5 is to be tightened up to torque 35 lb in 4 Nm no lock liquid is to be used in this case Load on the brake control handle and its play can be adjus...

Page 65: ... of leakage nearby the brake calipers C9997205U Caliper Fig 1 c visually before flight Check the system for operating before flight Check brake disks for correctness of their shape dents bends nicks signs of oil and other liquids Ensure the brake discs have a little amount of free motion along the guide pins See Fig 1 d B C9997205I Pin for brake disk A distance for free motion Check thickness of b...

Page 66: ...1 Revision No 3 Date 14 Sep 2008 4 2 3 3 5 Inspection of Brake Controls Fig 2 Remove the access panel KA6010001 Access Panel for inspection For that remove the knobs item 2 Fig 2 using a hex nut wrench 4 from the levers items 1 Fig 2 and unscrew the four screws C9996161 Screw ISO 7380 M5x12 ...

Page 67: ...hat while installing the brake system lines the tee fitting С9997205Q that distributes fluid between the left and right wheels must be shifted towards the left wall of the tunnel in order to ensure free access to the check valve C9997257D Check valve L RV6 11 1 8 MSv Fig 4 Operation of the brake system is based on functioning of KA7030100 Brake cylinder item 3 Fig 3 Fig 4 C9997419A Fuel valve K MI...

Page 68: ... item 1 Fig 2 and Fig 3 is in most forward position Make sure the aircraft is not set on parking brake i e the valve C9997419A Fuel valve K MI 561 1 8 22 II MSV Fig 2 and Fig 3 is open and the handle of the valve is aligned to aircraft longitudinal axle Place a can under the tank item 1 Fig 1 C9997813G Fuel Filter 5 16 to collect brake fluid in case of overfilling Fig 5 To fill the brake system do...

Page 69: ...no air bubbles are seen and the capacity C9997813G Fuel Filter 5 16 item1 Fig 1 is full 20 Make sure the brake disks and pads are dry and clean 21 Check brakes for operating 2 to 3 times before flight while warming up the engine and taxiing 4 2 3 5 Brake Pads Replacement 4 2 3 5 1 Type of Maintenance Line 4 2 3 5 2 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or...

Page 70: ...re super imposed with the flap controls as the ailerons are deflected when the flaps are set Control rods run from the mixer upwards behind the main frame where the associated bell cranks on the wing root rib are activated via a torsion shaft and a connecting rod The following diagram depicts the aileron controls orange and flap controls turquoise in the fuselage with mixer and with connection to ...

Page 71: ...p control systems were updated All elements of the Control systems were installed and starting from the airplane S N 08 03 05 except for planes 08 03 07 08 03 08 08 03 09 08 03 10 08 03 11 where the previous system still was installed During these changes was update flap actuator bracket and aileron droop mixer Modification of Aileron and Flap control systems see in following photo 1 Photo 1 ...

Page 72: ... 3 1 4 General A Unless otherwise specified the instructions below concern both right and left ailerons B To increase reduce length of a rod 1 Release the rod tips having loosened the locking nut by an 8x10 wrench 2 Take care that the tips are screwed into the threaded adjuster bushing body at least 5 16 8 mm 3 Unscrew screw in the rod tip a half turn 180 on each of the rods 4 Check rod length 5 R...

Page 73: ...KW2030020R for the right wing or KW2030010L and KW2030020L for the left wing for play In case of play torque the bolts С9996221 Bolt DIN 7991 M5x16 A2 to 49 lb in 5 5 Nm by a hex nut wrench 3 and bolts С9996286К Bolt DIN 912 M6x16 A2 to 80 lb in 9 Nm by a hex nut wrench 5 4 3 1 5 4 Wing bracket bearings inspection Inspect the bearings С9997022 Spherical Bearing EGLM for play Do not lubricate them ...

Page 74: ...ease MP Mobilux 3 Mobil Oil Corp Energrease LS 3 British Petroleum Co Beacom 3 Esso as necessary 4 3 1 6 Aileron Installation 4 3 1 6 1 Type of Maintenance Heavy 4 3 1 6 2 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher Flight Design task specific training required Put the wing top skin down onto a horizontal surface Inspect per section 4 3 1 7 Match hole...

Page 75: ...0 wrenches to 80 lb in 9 Nm Fig 2 and with one 8x10 wrench and one 5 hex nut wrench to 80 lb in 9 Nm Fig 3 Fig 4 Apply 1 or 2 drops of Bonding liquid middle strength Loctite 243 onto the threaded part of 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...

Page 76: ...985 M6 regular by a 10 wrench and 5 hex hut wrench Disconnect the rod KA6020030R from the internal bellcrank Fig 5 Connect the rod 3 KA6020030R with the bearing 1 С9997006А Rod end bearing ext thread GA6 that is fixed to the aileron root rib as shown Fig 6 Fig 6 Connect the aileron rod 1 KA6020030R with internal bellcrank Fig 5 Engage but do not tighten the nut on the bolt ...

Page 77: ...e the internal bellcrank must be set so that the line between the rod КW6020010 mounting hole and bellcrank axle of rotation is parallel to the rib of the wing Otherwise correct internal bellcrank positions by adjusting length of the КW6020030R rod disconnect the rod КW6020030R from internal bellcrank and aileron and adjust length of the rod per section 4 4 1 B Take care that the tips are inserted...

Page 78: ... 2008 Install the wings 1 and 2 onto the fuselage Fix them by the main bolts 3 КА2000010 Fig 8 While installing the wings make sure that the pin in the flap root bracket 1 КА2040010L for the left wing KA2040010R for the right wing gets into slot in the tip of the flap rod 2 КА6030200 Transverse rod Fig 9 Fig 8 Fig 9 ...

Page 79: ...cific training required 4 3 1 7 3 Rigging Aileron Zero Position Zero position of the ailerons is the position when the ailerons are aligned to the flaps in 6 12 cruise configuration 1 Set the flaps in 6 12 cruise position 2 Fix the control sticks Fig 10 in neutral position sticks must be vertical when seen from behind perpendicular to tube under the pyramid The fork rod Fig 11 must be in neutral p...

Page 80: ...eft wing KA6020050R for the right wing with bellcrank 2 КА6020040L for the left wing KA6020040R for the right wing by the bolt 3 КА6020021 Engage the nut 5 C9996334 Self locking nut DIN 985 M6 regular onto the bolt 3 but do not tighten Fig 7 5 Check zero position of the ailerons If the ailerons are not aligned with the flaps disconnect the rod КА6020030R for the right wing КА6020030L for the left ...

Page 81: ...ging the length of the rods in the system of aileron control vertical rods pos 1 and short rods in the wings If the length of the vertical rods pos 2 is not enough for the old control system it is possible to use short rods pos 5 The rod lengths pos 5 must be adjusted equally 3 In the old system aileron droop flaps in position 35º can be adjusted by changing the length of the short rods pos 3 4 4 ...

Page 82: ...tion 6 or 12 6 is required for CTLS registered within USA as LSA aircraft In this position the trailing edges of aileron and flaps must coincide see photo 1 Photo 1 Step 2 Put the pattern on the flap see photo 6 Deflect the aileron in upper position by control stick Place between markers on the pattern must coincide with the aileron trailing edge see photo 2 Markers on the pattern define boundary ...

Page 83: ...r position by control stick Place between markers on the pattern must coincide with the aileron trailing edge see photo 3 Markers on the pattern define boundary values of maximum deflection angle Photo 3 Using ruler instead of deflection template Measure the distance between same corners lowest or topmost on the rear edge of the flap and on the aileron see photo 3 1 ...

Page 84: ... Inspect per section 4 3 1 7 2 Check aileron deflection section 4 3 1 10 1 3 Tighten the rod tip locking nuts by an 8x10 wrench unscrewing them from the tip towards the rod per section 4 3 1 6 B for all rods that have been re adjusted 4 After adjustment the elements of the ailerons control system must not touch the elements of fuselage construction and flaps control system elements 5 Torque bolts ...

Page 85: ...ad limiting device was in operation If extension speed is below the maximum speed for flap extension as given in the handbook the next Flight Design service station should be contacted The flap control circuit breaker is to be found directly adjacent 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...

Page 86: ...6334 Self locking nut DIN 985 M6 regular are to be tightened to 80lb in 9 Nm and C9996333 Self locking nut DIN 985 M5 regular to 49 lb in 5 5 Nm 3 Set the fuselage so that fuselage roof is horizontal Check it by a level that must be perpendicular to the wing saddle area root rib Installation or removal of the flaps requires one person Setting of flap deflections requires two persons 4 3 2 4 Inspec...

Page 87: ...5 Nm by a hex nut wrench 3 and bolts С9996286К Bolt DIN 912 M6x16 A2 to 80 lb in 9 Nm by a hex nut wrench 5 4 3 2 4 4 Wing bracket bearings inspection Inspect the bearings С9997022 Spherical Bearing EGLM for play Do not lubricate them with anything If play exceeds 256 5 0 5 mm replace the bearing С9997022 Spherical Bearing EGLM For bearing installation use Loctite 480 Check if there is KA2010008 b...

Page 88: ...Aircraft Maintenance RLSA M or higher Flight Design task specific training required 4 3 2 5 3 Procedure 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 КА2020006 but do not fix the ...

Page 89: ...e bolts 3 КА2020007 Fig 3 3 КА2020006 Fig 2 Fig 4 Use new nuts only Torque the nut with one 8x10 wrench and one 5 hex nut wrench to 80 lb in 9 Nm Fig 2 Fig 3 and Fig 4 While installing the wings make sure that the pin at the root flap bracket 1 КА2040010L R got into connection with the tip of the flap rod 2 КА6030200 Transverse rod Fig 5 Check connection between the flap bracket and the tip of the...

Page 90: ...32 Self locking nut DIN 985 M4 regular by a 7 wrench towards the head of the bolt and release the bolts C9996026 Bolt DIN 912 M4x 20 8 8 Fig 7 2 Unscrew the bolts C9996026 Bolt DIN 912 M4x20 8 8 5 turns from the flange of the flap rod KA6030220 Transverse rod tube left by a 3 hex nut wrench Fig 7 3 Unscrew the nuts C9996333 Self locking nut DIN 985 M5 regular from the bolts С9996042 Bolt DIN 912 M...

Page 91: ...nly new nuts Put the washer С9996503 under the nut C9996333 Self locking nut DIN 985 M5 Repeat for all bolts Fig 5 7 Set the flap position indicator to zero 8 Inspect connection of the tip KA6030201 and the flap rod КА6030210 and КА6030220 Transverse rod tube for play In case of play replace the rivets 3 С9996653 Stainl steel rivet A2 4x11 5 to next bigger ones Fig 8 Eventually diameter of the riv...

Page 92: ...ss SW1 to input data into the PCB memory If the operation has been performed correctly the display shows the value set by SW3 5 Move the flap by SW2 to the next required position using a level Change the value at the screen by SW3 according to the value at the level Press SW1 to save settings into the memory 6 Repeat the process for each of the flap positions 7 If you cannot adjust set max angles ...

Page 93: ...l values and allowable tolerances in the Appendix of this maintenance manual Step 1 Set flaps in zero position Step 2 Put the level on upper surface of the flap see photos 1 and 2 and note the measured value Repeat this operation for the second flap Photo 1 Photo 2 Step 3 Set flaps to negative 12 or 6 for USA registered LSA aircraft Put the level on upper surface of the flap in the same place than...

Page 94: ...lection for each individual flap Using ruler instead of deflection template Measure distance between same corners lowest or topmost on the rear edge of the flap and on the rear edge on the flap tip on the fuselage see photo 3 1 Photo 3 Step 6 Set flaps to maximum positive deflection 35 Step 7 Put the level on the upper surface of the flap in the same place that point 2 see photo 4 Note down the de...

Page 95: ...ce between the noted zero deflection value and the negative deflection value provided the angle of defvlection for each individual flap Using ruler instead of deflection template Measure distance between same corners lowest or topmost on the rear edge of the flap and on the rear edge on the flap tip on the fuselage see photo 5 and 6 Photo 5 Photo 6 ...

Page 96: ...he flap max up position 3 While the actuator is moving press the up limit switch by a screwdriver The actuator must stop then 4 Release the up limit switch The actuator must move up to the flap max up position 5 Replace the Microswitch С9997198B Miniature switch if it does not work per items 3 and 4 Inspection of the down limit switch Fig 10 1 Set the flaps in the flap max up position 6 or 12 2 Se...

Page 97: ...nimum Level of Certification Required Repairman Light Sport Aircraft Maintenance RLSA M or higher 4 3 3 3 3 Procedure Set the plane on parking brake Ensure good access to the rear part of the fuselage Match the hole in the bearing of the bracket КА3020030 1 with the pin КА3020022 2 of the rudder lower support КА3020020 3 Match the hole of the slider bearing MFM 0610 06 4 of the upper bracket КА302...

Page 98: ...urn the rudder left up to the stop and set the rudder left cable 1 Prior to that the bushings КА6050001 2 are to be installed from both sides of the thimble and tightened by the screw DIN 7991 М6х30 8 8 3 to the rudder lower support КА3020020 4 using a hex nut wrench 4 Use lock liquid of middle strength Loctite 243 for the screw ...

Page 99: ... Inspection Procedures Manual Type CT Series CTLS LSA Page 4 62 AF 04800001 Revision No 3 Date 14 Sep 2008 Fig 2 Turn the rudder right up to the stop and repeat the process for attaching the right cable to the rudder ...

Page 100: ...of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher Flight Design task specific training required Fig 3 Rudder deflection angles are defined by the stops KA4010004 Fig 3 Distance between the plate with a hole for the steering rod on the engine mount and the front edge of the stop has to be about 3 4inch 20 mm The nose wheel has to be aligned along the aircraft and the peda...

Page 101: ...7 DIN 912 M6x20 8 8 using lock liquid of middle strength Loctite 243 7 To reduce angle of deflection to the right move the stop KA4010004 on the right rod KA4010400R The rest of the process repeats items 1 and 3 through 6 To change angle of deflection to the left repeat items 1 through 7 for the stop on the left rod KA4010400L Fig 4 4 3 3 4 3 Measuring Rudder Deflection Any adjustment of the flap ...

Page 102: ... side by pushing the pedals up to the stop Deflection angle can be read from the template Using ruler instead of measuring template Position a pointer marking the rear lower edge of the rudder in the neutral position Then deflect rudder by pushing the pedals up to the stop and measure distance between pointer and deflected rear edge of the rudder see photos 4 Photos 4 ...

Page 103: ...nel КВ1081300 2 from the instrument board 1 Fig 5 Fig 5 2 To move rudder neutral position to the left loosen by two 10x13 wrenches the nuts DIN 985 М8 1 which tighten the stop plate КА6050206 2 on the returning mechanism КА6050200 3 Fig 6 Fig 6 3 Move the stop plate КА6050206 2 towards the engine 0 4 0 8 inch 1 2 mm and tighten it again by the nuts М8 1 Fig 6 using a two 10x13 wrenches ...

Page 104: ...f the rudder the rudder axle must coincide with the plane axle Fig 7 Repeat item 3 if necessary Fig 7 5 Shifting rudder neutral position to the right can be done in the same way as shifting rudder neutral position to the left but the stop plate КА6050206 2 has to be moved away from the engine Fig 8 Fig 8 4 3 3 4 5 Adjusting of Control Cable Tension ...

Page 105: ...heck that the male rod end C9997006B Rod end bearing ext thread GA8 could be threaded into the rod KA4010400L R Rod left right more than 64 15 inch 6 mm 3 Unscrew the male rod end C9997006B Rod end bearing ext thread GA8 a half turn 180 on each of the rods 4 Preliminarily fix the rods KA4010400 L R on the KA4010001 Rocker by the screws C9996218 5 Check rudder cables tension 11 75 0 25 kgf 6 Repeat...

Page 106: ...8 Lock the threaded adjuster bushing by safety wire To increase cables tension perform items 1 through 8 having reversed tip rotation for the operation 4 4 3 3 5 Verification of Rudder Installation and Adjustment 1 Set the nose wheel along the longitudinal axle of the plane a Make sure the right and left pedals are on the same line b The rudder must be in neutral position along the plane axle c Th...

Page 107: ...railing edge of the horizontal tail covers 90 of the elevator span It is aerodynamically optimally attached to the fin by an elastic composite hinge It is activated through kinematical coupling when the elevator is deflected In this way the anti tab deflects n the same direction as the elevator thus improving elevator effectiveness and generating a tangible force on the control stick Warning When ...

Page 108: ...raft Inspect metal parts and especially welding seams for cracks and dents Inspect fasteners and axles for nicks and their threads for condition Ensure only new self locking nut DIN 985 are used Check if the sheave is greased enough Ensure the free motion of the sheave on the axle Inspect composite parts for cracks paint delamination and mounting holes for ovaling where bolts pivots and bearings a...

Page 109: ...Install the stabilator bracket with balancer KА3010120 pos 1 onto the stabilator KA3010200 Fig 1 Make sure the trim tab is installed on the stabilator the control rods КA6060010 Rod are connected to the trim tab the stabilator bracket is equipped with trim tab bell crank КА6060100 and sheave pos 2 2 Match holes pos 3 in the bracket with holes in the upper and the lower skins of the stabilator 3 Se...

Page 110: ... Check lock rings C9997032 Lock ring DIN 472 22x1 Fig 2 that secure the bearings C9997025 Bearing SKF 608 2RZ on both sides of the fuselage are present Check inner cage of the bearings C9997025 for free rotation Replace bearings if necessary Fig 2 2 Lubricate the axle of rotation KA3010001 by CIATIM 201 or Aeroshell Grease 6 SHELL Unirex S 2 Esso Eneryrease LCI LT 2 British Petroleum Make sure tha...

Page 111: ...acket 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 50 Secure KA3010011 Bearing bodies by tightening new nuts C9996333 Self locking nut DIN 985 M5 to torque 94 lb in 5 5 N m on bolts C9996207 Bolt DIN 7991 M5x16 8 8 9 Following Fig 3 stretch the saf...

Page 112: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page 4 75 AF 04800001 Revision No 3 Date 14 Sep 2008 Fig 3 ...

Page 113: ... Make sure that lock nuts on the rods of the trim tab and the bellcrank are tightened to 49lb in 5 5 N m the lock nuts in front of C9997004 Rod end bearing int thread SI6E are tightened to 80lb in 9 N m 22 Check the proper reaction of the trim tab on the moving of the throttle box steering wheel Moving the wheel forward trim tab deflects upwards backward trim tab deflects downwards 23 Lock the tur...

Page 114: ...or deflection can be adjusted by bushings КА6040007 Bushes Fig 5 Unscrew 2 3 turns the lock nuts С9996334 by two 10x13 wrenches to unlock the bushing КА6040007 Bushes for adjusting Stabilator deflection down to increase angle of deflection down screw the aft bushing КА6040007 Bush Fig 5 from КА6040008 to reduce angle of deflection down screw the aft bushing КА6040007 Bush Fig 5 onto КА6040008 as n...

Page 115: ...ightening it by 10x13 wrench to 80lb in 9 N m 4 3 4 5 3 Measuring Stabilator Deflection Any adjustment of the flap control system must be documented in an adjustment report You can find the template starting the nominal values and allowable tolerances in the Appendix of this maintenance manual Step 1 Set stabilator to neutral Neutral positioon is achieved when the stabilizer leading edge coincides...

Page 116: ...ith the control stick control stick up to forward rearward stop the stick Note detected values and determine deflection in refernce to the value read at neutral deflection see photos 4 and 5 Photo 4 Photo 5 Using ruler instead of scale Set two coinciding markings on the stabilator and on the fuselage Deflect the stabilator and measure the distance see photos 6 ...

Page 117: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page 4 80 AF 04800001 Revision No 3 Date 14 Sep 2008 Photos 6 ...

Page 118: ...t angles of deflection as required Fig 3 Upon completion of adjusting tighten the nut C9996333 Self locking nut DIN 985 M5 to 49lb in 5 5 N m by screwing it towards the tip Any adjustment of the flap control system must be documented in an adjustment report You can find the template starting the nominal values and allowable tolerances in the Appendix of this maintenance manual Step 1 Set stabilato...

Page 119: ...Step 4 Select maximum tail heavy trim Determine deflection of trim tab with stabilator in neutral Step 5 Deflect stabilator nose up Determine deflection of trim tab Step 6 Select maximum nose heavy trim Determine deflection of trim tab with stabilator in neutral Step 7 Deflect stabilator nose down Determine deflection of trim tab ...

Page 120: ...he 6 bolts Fig 6 pos A have to be screwed in but not tightened The stabilator bracket and axle are to be set on some supports so that the stabilator could freely wobble around the axle of rotation To reduce balancer weight Screw out the 6 bolts pos A Take off the necessary quantity of the lead fraction from the inside of the balancer Fig 6 pos B and check balance with the bracket installed onto th...

Page 121: ...on 4 2 1 7 For checking use template from Appendix I Check push pull cable attachments C9997092 Push pull cable TIPO 70 Fig 7 for presence of grease Multipurpose plastic grease LITOL 24M ТУ 0254 015 00148820 99 Retinax EP 2 Alvania EP 2 SHELL Alvania Grease R3 Petroleum Co Ltd Mobilgrease MP Mobilux 3 Mobil Oil Corp Energrease LS 3 British Petroleum Co Beacom 3 Esso Check all bolts for tightness a...

Page 122: ...aper 800 mm Sandpaper 400 mm Sandpaper 240 mm Sandpaper 120 mm Sandpaper 80 mm Sandpaper 50 mm Paint gun nuzzle 1 6 mm Polishing paste Poly Glanz Polishing Creme Glanz 4 5 2 The parts needed to perform the task None 4 5 3 Type of Maintenance Heavy 4 5 4 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher Flight Design task specific training required 4 5 5 Put...

Page 123: ...utes for internal surfaces of the fuselage doors baggage doors and rescue system hatch for 1 5 2 hours As soon as the first layer of paint gets dry apply the second layer of paint mixture minimally needed to cover the first one Paint mixture consumption should not exceed 0 031PSF 150g m2 Place the part into a compartment with temperature at least 65 F 18 С for 30 minutes for internal surfaces of t...

Page 124: ...thorizations on a case by case basis may be required Contact Flight Design for details 5 2 Rotax 912ULS Engine For engine inspection and maintenance refer to the valid original Rotax manuals Initial manuals are supplied with the aircraft Operator s Manual for all versions of ROTAX 912 Maintenance Manual Line Maintenance for ROTAX Engine Type 912 Series Maintenance Manual II Heavy Maintenance for R...

Page 125: ...ired Steel rope 1 5 mm 39 4 in 1 m Air filter 1 pcs Wraps 6 pcs 5 3 3 Type of Maintenance Line 5 3 4 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher 5 3 5 General Remove upper and lower cowling to ensure good access to the firewall forward area Set the plane s parking brake on Put wheel chocks under the main wheels to prevent rolling 5 3 6 Inspection of C...

Page 126: ... 3 Fig 1 by 6 bolts 6 Release the clamps by a screwdriver and disconnect the hose from the air filter box pos 2 Fig 1 and the airbox pos 1 Fig 2 Fig 2 7 Replace the damaged hose to a new one of the same length if required 8 Connect the hose to the air filter box pos 2 Fig 1 and the airbox pos 1 Fig 2 Tighten the clamps Fig 3 b Check carb heat valve operation on airbox a When the handle is pushed F...

Page 127: ...e carb heat is not activated when the handle is pulled out Fig 4 b do the following Release the stop by a screwdriver and tighten the cable Secure the stop using a screwdriver Check the control handle for operation per item b If positive continue with item e e If the carb heat is activated but the handle is not fully pulled out do the following Mark length on the handle it can be pulled more dista...

Page 128: ...the upper winglets The vent tube is led through the outer tank section in a loop In this way no fuel can escape into the vent tubes should the aircraft be parked at a slant As the tubes are coupled equal pressure prevails in both tanks even when the winglets experience different flow conditions Each tank outlet has a coarse screen which can be removed via a maintenance flap in the root rib for vis...

Page 129: ... right Right wing Flapper valve Flapper valve Sloshing rib with ventilation Tank ventilation A pillar left A pillar right Carburetors 2 Fuel pump engine driven Gascolator Firewall Fuel fine filter Flowmeter Fuel shutoff valve Sloshing rib with ventilation Tank ventilation X Filler cap Filler cap Coarse fuel inlet filters Fuel backflow NACA nozzle in winglet Drain valve Left wing NACA nozzle in win...

Page 130: ...inspection see paragraph 6 7 for details Min rate is 0 88 pint 0 5l per 45 sec 3 Check Intake filters inside the fuel tanks every 1000 hrs or at negative result from 100 hr flow checking see chapter 6 8 for details 4 Inspect the fuel ventilation holes on the wingtips Fig 5 for cleanness and obstruction not less than 1 time after 100h 5 Inspect connections for leaks 6 Inspect the fuel tank and fuel...

Page 131: ...e 3 Fill in a right wings tank with not less than 5 liters of fuel Open a gascolators drain valve Fuel should drain by gravity If it is not create superfluous pressure in a tank which would promote the fuel drainage After the fuel starts to flow down remove the superfluous pressure in a tank Inspection checking the fuel pipe throughput Fuel should drain from a gascolator by gravity with the charge...

Page 132: ...AF 04800001 Revision No 3 Date 14 Sep 2008 fuel hoses absence of fuel system blockage Start the engine Keep the engine working during 5 10 minutes Stop the engine Repeat items 6 9 Fig 1 Fig 2 Note CTSW photos are used for illustration only applies in the same way to CTLS aircraft ...

Page 133: ...6 on the access panel КA7020002R L Cap plate unscrewed 1 2 turn and then unscrew them fully Remove the fuel tank access panel КA7020002R L Make sure there are no foreign objects within visible and convenient for touching areas of the fuel tank Inspect the check valve through the side access panel for operation of and no foreign objects inside the tank and on the surface of the mesh To check it uns...

Page 134: ... tube is turned towards the trailing edge of the wing and is in the lowest position lays on the bottom skin Set the washers C9996504 DIN 125 A2B 6 4 mm onto the bolts NOTE use only new nuts C9996334 each time the fuel tank access panel is to be installed Pre tighten the nuts C9996334 cross wise by a 10x13 wrench and then finally tighten the nuts going from one to another Fig 3 Fig 4 ...

Page 135: ...l of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher 6 7 3 Procedure Fig 5 Inspect for 1 Leaks at joint of the connector Fuel Filter 5 16 Fig 5 unit 1 and hose Fuel tube DIN 73379 7 5x13 0 Tighten the clamp Fig 5 unit 2 if necessary 2 Filter body integrity 3 Foreign objects inside the filter The filter must be replaced latest every 200h or earlier on condition ...

Page 136: ...ons 2 For passing fuel through the lines and water in fuel by draining some fuel through the drain valve item А Fig 6 3 For foreign objects in the gascolator Unscrew the nut item В Fig 6 remove the bail and remove the body ensure integrity of the O ring that recovers its sizes upon some time needed to get it dry Assemble the gascolator in reverse o the disassemble process 4 Fire Protection Hoses C...

Page 137: ...Date 14 Sep 2008 7 Propeller 7 1 Type of Maintenance Line 7 2 Minimum Level of Certification Repairman Light Sport Aircraft Maintenance RLSA M or higher 7 3 Propeller Maintenance Procedures For propeller inspection and maintenance refer to the latest maintenance manual issued by the propeller manufacturer ...

Page 138: ...997056Е Nicopress stop sleeve 1 5 1 7 mm for 1 6 mm cable 1 pcs С9997703В Spring 0 5x5 0x25 0 1 pcs С9993188 AERODUCT tube CEET 7 1 3 4 ID 59 in 1 5 m C9997727F TY wraps CV 200 white 2 pcs 8 3 Cabin Heat System For inspection and maintenance of the heating system one person is required 8 3 1 1 Type of Maintenance Line 8 3 1 2 Minimum Level of Certification Owner Pilot 8 3 1 3 Procedure Set the pla...

Page 139: ... Fig 3 а the Cabin heater choke КА7040200 Fig 3 b is ON Fig 3 a Fig 3 b 3 If the cabin heater choke does not operate inspect the connecting cable between the choke and the handle and eliminate damage as follows a Check if there is the spring С9997703В Spring 0 5x5 0x25 0 at the Cabin heater choke КА7040200 If the spring is missing or damaged set a new one Fig 4 ...

Page 140: ...trument board using 3 hex nut wrench and check the cable С9997065В Steel rope 7x7 1 mm for fraying and if there is the sleeve С9997056Е Nicopress stop sleeve 1 5 1 7 mm for 1 6 mm cable at the cable attachment to the handle Fig 5 e If the sleeve С9997056Е Nicopress stop sleeve 1 5 1 7 mm for 1 6 mm cable is missing connect the cable С9997065В Steel rope 7x7 1 mm to the handle and secure it with th...

Page 141: ...С9997816С Cable stop 1806 Z ni a little by a screwdriver and tighten the cable С9997065В Steel rope 7x7 1 mm NOTE the stop can move along the cable when the bolt is not tightened b Secure stop 9997816С Cable stop 1806 Z ni position by a screwdriver c Proceed to item 4 6 If the choke КА7040200 is at OFF position and the handle is not fully pulled out do the following a Mark on the handle length it ...

Page 142: ...D 1 long piece in the engine compartment 1 long piece in the cabin under the instrument board 2 and the short piece 3 between the Cabin heater choke КА7040200 and КВ7040400 Air branch canal Fig 7 If no damages are found proceed to item 8 otherwise replace the damaged hose as follows a To replace the damaged hose С9993188 AERODUCT tube CEET 7 1 3 4 ID in the cabin do the following a Unscrew the bol...

Page 143: ...T 7 1 3 4 ID near КВ7040300 Air mixer under the instrument board Fig 8 c 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 d Tighten the clamps С9997723 Clamp 40 60 by a cross screwdriver or wrench with header 7 Fig 8 b To replace a damaged hose in the e...

Page 144: ...ase the clamp С9997723 Clamp 40 60 that secures the hose С9993188 AERODUCT tube CEET 7 1 3 4 ID near the heating Cabin heater choke КА7040200 Fig 9 b Unscrew the bolt С9996053 Bolt DIN 912 M6x10 8 8 by a hex nut wrench 5 and remove the shield КА5030001 Protection plate left c Unscrew the bolt С9996053 Bolt DIN 912 M6x10 8 8 by a hex nut wrench 5 and remove the shield КА5030002 Protection plate rig...

Page 145: ...heater КU7040120 Air heater Fig 9 i Replace the damaged piece 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 j Attach the hose С9993188 AERODUCT tube CEET 7 1 3 4 ID to the heater КU7040120 Air heater k Tighten the clamp С9997723 Clamp 40 60 by a screwdriver or wrench with header...

Page 146: ...hat secures the hose С9993188 AERODUCT tube CEET 7 1 3 4 ID near the Cabin heater choke КА7040200 Fig 7 w Unscrew the bolts С9996283С by 8 wrench Remove the clamp КА704004 Clamp and the Cabin heater choke КА7040200 from the engine mount x Remove КВ7040400 Air branch canal y Replace the damaged piece of hose С9993188 AERODUCT tube CEET 7 1 3 4 ID to a new one of the same length Pass the hose throug...

Page 147: ...5 Chapter 3 9 3 4 Glass Cockpit Dynon EFIS 100 Except for regulatory periodic checks and an annual internal battery capacity test if optional internal emergency battery is installed maintenance of the EFIS D100 is on condition only 9 3 5 Glass Cockpit Dynon EMS D120 Dynon Avionics products incorporate a variety of precise calibrated electronics Except for replacing the optional internal backup bat...

Page 148: ...is section VOR Checks Even though the SL30 is designed to utilize the most state of the art DSP technology and maintain a very high accuracy and repeatability record it still must undergo the VOR accuracy checks as required by the applicable requirements The last VOR check information may be entered into the SL30 via the system mode VOR Check See the Garmin SL30 operator s manual for details Refer...

Page 149: ...nsure continued reliability of your ELT it must be inspected for damage and wear which could be caused by age exposed elements vibrations etc The inspections must be performed a minimum of one time each 12 months The Ameri King Corp Model AK 450 ELT is designed to use only Duracell MN1300 Alkaline Batteries which are dated by the Manufacturer Battery replacement is required upon reaching the date ...

Page 150: ... Inspection of Pitot Static Port 9 4 1 Type of Maintenance Line 9 4 2 Minimum Level of Certification Owner Pilot 9 4 3 Procedure At every 100 hrs inspection inspect the system for obstruction as follows Take the Pitot tube C9997455Q Pitot tube out of the wing Fig 1 clean it remove insect debris and so on using a stick Fig 1 ...

Page 151: ... instrument the ends are to be connected to Carefully blow out the systems by compressed air with little pressure Install the Pitot tube C9997455Q into the wing Connect the tubes С9993190Н PTFE tube 6x1 to the instruments according to the tags 9 5 Special Equipment Maintenance of special equipment like comm transceiver transponder GPS autopilot attitude gyro directional gyro and etc must be carrie...

Page 152: ...nch 3 1 pcs Hex nut wrench 4 1 pcs Hex nut wrench 5 1 pcs Multimeter 10 2 Materials Required Multipurpose plastic grease LITOL 24M ТУ 0254 015 00148820 99 Retinax EP 2 Alvania EP 2 SHELL Alvania Grease R3 Petroleum Co Ltd Mobilgrease MP Mobilux 3 Mobil Oil Corp Energrease LS 3 British Petroleum Co Beacom 3 Esso 10 3 General One person is required for inspection and maintenance Prior to beginning s...

Page 153: ...components of the electric system within engine compartment are shown on Fig 2 Fig 2 Electric instruments control switch panel ignition starter switch and circuit breakers are located on the central console and shown on Fig 3 Unscrew the bolts attaching the instruments panels by a screwdriver to ensure access to the studs and lines ...

Page 154: ...Procedures Manual Type CT Series CTLS LSA Page 10 3 AF 04800001 Revision No 3 Date 14 Sep 2008 Fig 3 To inspect the relais board of the flap controller located at the firewall remove one of the side instrument panels Fig 4 Fig 4 ...

Page 155: ...ore it in a warm dry place Never leave the battery discharged Provide adequate ventilation when charging or using batteries in an enclosed space keep sparks flames and cigarettes away Do not replace the sealed lead acid battery with a wet lead acid battery Never jump start an aircraft that has a dead or discharged battery It takes approximately three hours to recharge a fully discharged battery wi...

Page 156: ...S 3 British Petroleum Co Beacom 3 Esso onto the ground Fig2 4 and battery terminals 10 4 Battery Replacement 10 4 1 Type of Maintenance Line 10 4 2 Minimum Level of Certification Owner Pilot 10 4 3 Procedure Refer to battery manufacturer s instructions for batteries other than the one specified To remove battery refer to Fig 2 1 CAUTION To reduce the chance of personal injury and possible equipmen...

Page 157: ... Template for Trim Tab Deflection Angles Measurement For checking trim tab deflection angles 1 Cut out two parts of template and glue them together through A A line 2 Glue prepared template on the appropriate surface for example 3 4 mm polycarbonate and cut it out 3 Use prepared template for verification of trim tab deflection angle ...

Page 158: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page AI 2 AF 04800001 Revision No 3 Date 14 Sep 2008 ...

Page 159: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page AI 3 AF 04800001 Revision No 3 Date 14 Sep 2008 ...

Page 160: ...own mm 52 mm Tol 6 mm 6 mm is 12 degrees Aileron right up deg 26 5 deg Tol 1 5 deg 1 5 deg Aileron and flap zero position up mm 109 mm Tol 6 mm 6 mm is 12 degrees Aileron right down deg 12 5 deg Tol 1 5 deg 1 5 deg Aileron and flap zero position down mm 52 mm Tol 6 mm 6 mm is 12 degrees Stabilizer up deg 14 deg Tol 1 deg 1 deg Stabilizer down deg 9 deg Tol 1 deg 1 deg Trim tab down deg 1 deg Tol 0...

Page 161: ... mm Tol 6 mm 6 mm is 6 degrees Aileron right up deg 26 5 deg Tol 1 5 deg 1 5 deg Aileron and flap zero position up mm 109 mm Tol 6 mm 6 mm is 6 degrees Aileron right down deg 12 5 deg Tol 1 5 deg 1 5 deg Aileron and flap zero position down mm 52 mm Tol 6 mm 6 mm is 6 degrees Stabilizer up deg 14 deg Tol 1 deg 1 deg Stabilizer down deg 9 deg Tol 1 deg 1 deg Trim tab down deg 1 deg Tol 0 5 deg 0 5 d...

Page 162: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page AIII 1 AF 04800001 Revision No 3 Date 14 Sep 2008 Appendix III Service Difficulty Report Form ...

Page 163: ...wheel 4 Inspect axle for integrity nicks dent cracks and pay specific attention to the threaded area of axle Replace axle if necessary 5 Inspect wheel rims for dents and cracks Replace if necessary 6 Inspect bearings condition 9 Inspect tube and tire for integrity Inspect tire for foreign object Inspect metal parts of wheel contacting with tube and tire for sharp edges and nicks Apply talcum onto ...

Page 164: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page AIV 2 AF 04800001 Revision No 4 Date 02 Jan 2009 Fig 1 Fig 2 ...

Page 165: ...4 Date 02 Jan 2009 2 Main Wheel 2 1 Main Wheel removal Unscrew bolt М6 item 1 fig 1 Unscrew 3 screws М5 item 2 fig 2 Remove wheel fairing Remove lock pin item3 fig 3 unscrew nut item 4 fig 3 Unscrew 3 screws item 6 remove nord lock washers item 7 fig 3 Detach brake disk from wheel Remove wheel Fig 1 Fig 2 ...

Page 166: ...nting follow requirements in compliance with Technical Service Guide MATCO mfg Fig 3 2 3 Inspection and Maintenance of wheels For Main wheel inspecting do following remove wheel Fig 4 unscrew 4 nuts M6 item 9 remove washers item 10 remove 4 bolts M6 item 11 fig 4 remove plate brake 12 caliper 13 wheel axle 14 distance plate15 fairing plate 16 Inspect rims for dents and cracks Replace if necessary ...

Page 167: ...ce and Inspection Procedures Manual Type CT Series CTLS LSA Page AIV 5 AF 04800001 Revision No 4 Date 02 Jan 2009 Fig 4 NOTE for mounting use only new nuts M6 item 9 Upon completion check brakes for functioning ...

Page 168: ...1 1 Screw DIN 912 M6x16 5Nm for mounting use bonding liquid middle strength 2 2 Screws ISO 7380 M5x16 5Nm 3 3 lock pin 3 4 4 wheel nut Technical Service Guide MATCO mfg 3 4 5 Main wheel 3 4 6 Screw 11Nm Technical Service Guide MATCO mfg 3 4 7 nord lock washer 3 4 8 Brake disk 4 9 Self locking Nut DIN 985 M6 9Nm 4 10 Washer 6 3 4 11 Bolt Din 912 M6 4 12 Brake plate 4 13 caliper 4 14 wheel axle 4 15...

Page 169: ... of main cylinder MC 4CT item 1 fig 1 brake valve item 2 fig 1 brake rode item 3 fig 1 handle activation item 4 fig 1 brake tubes items 5 fig 1 items 29 fig 1 items 30 31 fig 2 brakes item 6 fig 3 brake disk item 7 fig 3 Items and tightening torque see in following table Note Use only red aircraft fluid Mil H 5606 or other suitable petroleum or silicon based fluids During assembling or disassembli...

Page 170: ...be not less of tank visually add fluid if necessary 2 Check brake handle activation for play up to 2 sm if necessary adjust play with rod end item 10 fig 1 3 Check for sign of leakage nearby brake calipers brake lines connection fig 1 fig 2 fig 3 Replace connectors and sealing washers if necessary 4 Check system for operation 5 Check brake disks for correctness of shapes check for dents bends nick...

Page 171: ...rings Pay attention on joints of lines with caliper for damages leakiness Fig 4 Replace brake system control parts if necessary In case of unsatisfactory operation of brake system after followed by carrying out all said above operations immediately contact Flight Design for inspection and making decision on further action 3 3 Replacing of brake system parts For caliper brake pads brake disk replac...

Page 172: ...Maintenance and Inspection Procedures Manual Type CT Series CTLS LSA Page AIV 10 AF 04800001 Revision No 4 Date 02 Jan 2009 Fig 5 Fig 6 ...

Page 173: ... AF 04800001 Revision No 4 Date 02 Jan 2009 Brake conduits are opened at forward position of valve grip item 12 fig 7 Brake conduits are closed at sideward position of valve grip item 12 fig 8 System works forward grip position main brake sideward position parking brake Fig 7 Fig 8 ...

Page 174: ... Page AIV 12 AF 04800001 Revision No 4 Date 02 Jan 2009 Fig 9 Fig 10 Note In case of unsatisfactory operation of brake system after followed by carrying out all said above operations immediately contact Flight Design for inspection and making decision on further action ...

Page 175: ... with Fluid Visually check the system for integrity and tightness Make sure the brake control handle is in most forward position Make sure the aircraft is not set on parking brake i e the valve is open Place a can under the tank to collect brake fluid in case of overfilling Follow requirement and recommendation of Technical Service Guide MATCO mfg ...

Page 176: ...nk 1 7 8 12 Grip 1 13 Washer 5 3 1 14 Nut M5 5 5Nm 1 15 Screw M4 3 5Nm For mounting use bonding liquid middle strength 1 16 Bolt M5 1 17 Washer 4 2 1 18 Nut M4 3 5Nm 1 19 Screw M4 1 20 Distance bushing 6 9 21 Fitting FT0107 1 8 15Nm 5 6 22 Fitting FT0307 10Nm 5 6 9 10 23 Brake Line Nut M10x1 10Nm 2 10 24 Fitting B20010 Al M10x1 9 25 L fitting 1 8 10 Nm 9 26 Nut M10x1 10Nm 6 9 27 Washer B22001AL 6 ...

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