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FLIGHT DESIGN CTLS Series - User Manual

FLIGHT DESIGN CTLS Series
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CTLS
LSA
SERIAL NUMBER:_______________
Maintenance and Inspection Procedures Manual
THIS DOCUMENT AND THE TECHNICAL DATA HEREON DISCLOSED ARE PROPRIETARY TO FLIGHT DESIGN AND SHALL
NOT BE USED, RELEASED, OR DISCLOSED IN WHOLE OR IN PART WITHOUT EXPRESS WRITTEN PERMISSION FROM
FLIGHT DESIGN

Table of Contents

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Summary

General Information

Manufacturer Contact Information

Contact details for Flight Design GmbH.

US Contact Information

Contact details for Flight Design USA.

Care and Cleaning Procedures

Guidelines for cleaning composite aircraft materials.

Construction Materials

Details on materials used in aircraft construction.

Equipment List

Lists aircraft equipment and options.

Weight and Balance Information

Provides aircraft weight and balance data.

Fastener Torque Values

Details recommended torque values for fasteners.

General Safety Information

Provides general safety precautions for maintenance.

Reporting Safety Concerns

Procedure for reporting safety concerns.

Minimum Levels of Certification

General Certification Levels

Specifies minimum certification levels for tasks.

Certification Level Definitions

Defines certification levels used in the manual.

Required Levels Table

Overview table of certification levels per task.

Aircraft Inspections

Aircraft Records

Checklist for aircraft logbooks and records.

Run-up Procedures

Procedure for engine run-up before inspection.

Post-Run-up Checks

Tasks to perform after engine run-up.

Propulsion System Inspection

Inspection of the engine and related systems.

Fuselage Inspection

Inspection of the aircraft fuselage structure.

Wing Inspection

Inspection of aircraft wings and associated components.

Empennage Inspection

Inspection of the tail section (rudder, stabilator).

Landing Gear Inspection

Inspection of the aircraft landing gear system.

Cabin and Baggage Inspection

Inspection of cabin and baggage areas.

Inspection Completion

Final checks and record-keeping for inspections.

Structures Maintenance

Wing Maintenance

Details on aircraft wing structure and maintenance.

Landing Gear Maintenance

Procedures for landing gear maintenance.

Brake System Maintenance

Information about the aircraft brake system.

Flight Controls Maintenance

Procedures for flight control systems (ailerons, flaps, rudder).

Stabilator Maintenance

Information on the aircraft's stabilator system.

Structural Repair Procedures

Procedures for structural repairs on composite parts.

Painting and Coating Procedures

Procedures for painting and coating aircraft surfaces.

Engine Maintenance

Engine Systems Overview

Overview of engine systems and accessories.

Rotax 912 ULS Engine Procedures

Maintenance and inspection for Rotax 912ULS engine.

Carburetor Heat Control

Inspection and maintenance of the carburetor heat control.

Fuel System Maintenance

Fuel System General Information

General information on the fuel system.

Fuel System Inspection

General inspection procedures for the fuel system.

Fuel Flow Check and Simulation

Checking fuel flow and simulating engine restart.

Fuel Filter and Gascolator

Maintenance of fuel filter and gascolator.

Propeller Maintenance

Propeller Maintenance Procedures

Procedures for propeller inspection and maintenance.

Utility Systems Maintenance

Cabin Heat System

Inspection and maintenance of the cabin heat system.

Instruments and Avionics

Instrument Maintenance Procedures

General procedures for instrument maintenance.

Pitot & Static Port Inspection

Inspecting the pitot and static port system.

Special Equipment Maintenance

Maintenance of special avionics equipment.

Electrical System Maintenance

General Electrical System Procedures

General procedures for electrical system inspection/maintenance.

Battery Replacement

Procedure for replacing the aircraft battery.

Appendix I: Trim Tab Deflection Template

Appendix II: Adjustment Reports

Adjustment Report 1

Report template for control surface adjustments.

Appendix III: Service Difficulty Report Form

Appendix IV: MATCO Brake System

Nose Wheel Maintenance

Procedures for nose wheel maintenance in MATCO system.

Main Wheel Maintenance

Procedures for main wheel maintenance.

MATCO Brake System Details

Information on the MATCO brake system.

Filling MATCO Brake System

Procedure for filling the MATCO brake system.

FLIGHT DESIGN CTLS Series Specifications

General IconGeneral
ManufacturerFlight Design
ModelCTLS Series
CategoryLight Sport Aircraft
EngineRotax 912ULS
Horsepower100 hp
Service Ceiling4, 572 m (15, 000 ft)
Seating Capacity2
Propeller3-blade composite
Maximum Takeoff Weight600 kg (1, 320 lbs)
Cruise Speed207 km/h
Stall Speed65 km/h (40 mph)
Height2.3 m (7 ft 7 in)

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