CTLS-LSA with ROTAX 912iS

Supplement S3 to the

Airplane Maintenance Manual (AMM)

CTLS-LSA with ROTAX 912iS

Airplane Type : CT

Airplane Model : CTLS-LSA

Airplane Registration Number : _______________

Airplane Serial Number : _______________

Document Number

Date of Issue

: AF 0480 0011_00

: 05-Aug-12

This Manual is Approved on the Basis of Manufacturer Self Declaration

THIS DOCUMENT IS THE PROPERTY OF FLIGHT DESIGN

AND MAY NOT BE CITED, REPRODUCED, DISCLOSED OR DISTRIBUTED IN WHOLE OR IN PART

WITHOUT PRIOR EXPRESS WRITTEN PERMISSION OF FLIGHT DESIGN

Template No.: PZ 0100 0034_00

I RECORD OF SUPPLEMENT REVISIONS

Supplement revisions are provided by Flight Design GmbH as available. The updates shall be manually entered to the individual printed version of the AMM by the Pilot/Owner of the aircraft.

Supplement updates are provided in electronic format (pdf file) directly to aircraft

Pilots/Owners, when the Pilot/Owner leaves the correct contact information with Flight

Design GmbH. Supplement updates are also provided through the webpage of Flight

Design GmbH, in the section Service Documents: http://www.flightdesign.com/index.php?page=service .

It is the duty of the aircraft Pilot/Owner to ensure that the supplement contains all updates applicable to his aircraft serial number. Updates are done by manually removing invalid sections and inserting new or updated sections. Supplement update must be logged in the subsequent table.

Rev.

No.

Date

Sections

Removed

00 05-Aug-12 n/a

Sections

Inserted

all

Signature

No.

n/a

Date

Sections

Removed

Sections

Inserted

Signature

Document Title

Supplement S3 to the AMM CTLS-LSA –

CTLS-LSA with ROTAX 912iS

Approval Ref.:

Document No. Revision

AF 0480 0011 00

Date

05-Aug-12

Approved on the Basis of Manufacturer Self Declaration

Section

I-1

II LIST OF EFFECTIVE SECTIONS

Sect.

No.

Rev.

No.

Approval Reference

01-00 00 Self

02-00 00 Self

04-00 00 Self

05-00 00 Self

05-10 00 Self

05-20 00 Self

05-30 00 Self

11-00 00 Self

12-00 00 Self

28-00 00 Self

71-00 00 Self

73-00 00 Self

74-00 00 Self

75-00 00 Self

76-00 00 Self

77-00 00 Self

78-00 00 Self

79-00 00 Self

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

II-1

I RECORD OF SUPPLEMENT REVISIONS

II LIST OF EFFECTIVE SECTIONS

CHAPTER 01 – INTRODUCTION

CHAPTER 02 – ORGANIZATION AND HANDLING OF THE SUPPLEMENT

CHAPTER 04 – AIRWORTHINESS LIMITATIONS

CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK

SECTION 05-10 – TIME LIMITS

SECTION 05-20 – SCHEDULED MAINTENANCE CHECK

SECTION 05-30 – UNSCHEDULED MAINTENANCE CHECK

SECTION 12-10 – REPLENISHING

CHAPTER 28 – FUEL SYSTEM

CHAPTER 71 – ENGINE

CHAPTER 73 – ENGINE FUEL AND CONTROL

CHAPTER 74 – IGNITION

CHAPTER 75 – COOLING

CHAPTER 76 – ENGINE CONTROLS

CHAPTER 77 – ENGINE INDICATING

CHAPTER 78 – EXHAUST

CHAPTER 79 – OIL SYSTEM

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

III-1

Contents

01-00.1 General

01-00.2 Approval

CHAPTER 01 – INTRODUCTION

Contact

01-00.5 Recovery of Certification Data

01-00.7 Source to Purchase Parts

01-00.8 List of Disposable Replacement Parts

01-00.9 Recommended Torque Values

01-00.1 General

This Supplement to the Airplane Maintenance Manual (AMM) contains the data necessary to carry out the maintenance of the CTLS-LSA with ROTAX 912iS or iSc installed. This

Supplement contains a full description of the systems options and maintenance instructions thereof. The Supplement provides only the additional information that results from the differences of the ROTAX 912 iS or iSc engine installation. All other information of the basic Aircraft Maintenance Manual (AMM), that is not covered here, remain valid.

Use the following additional sources of information together with this AMM:

1. Applicable Service Notifications including referenced Service Instructions,

2. Applicable Service Bulletins including referenced Service Instructions,

3. Applicable Safety Alerts including referenced Service Instructions.

4. ROTAX 912 iS / iSc manuals issued by ROTAX for the affected engine S/N:

- Maintenance Manual (Line Maintenance) MML-912i

- Maintenance Manual (Heavy Maintenance) MMH-912i

▲Warning: This document is valid only for the aircraft S/N identified on the cover sheet (call-sign might change). It may not be transferred to any other operated aircraft.

▲Warning: This document may be applied only to CTLS aircraft that have been factory produced with the ROTAX 912 iS injection engine.

● Note: For simplicity reasons this manual will refer to the ASTM compliant engine version Rotax 912 iS. Any instructions provided in reference to this engine automatically applies as well to the otherwise technically identical Type Certified engine version Rotax 912 iSc, unless explicitly noted otherwise.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

01-00-1

01-00.2 Approval

The contents of this manual is approved on the basis of Manufacturer Self Declaration against the applicable ASTM industry standard.

The engine Rotax 912 iS is in compliance with ASTM F2339-06.

The engine installation to the airframe is in compliance with ASTM F2245-10c.

This supplement to the AMM is generated on compliance with ASTM F2483-05.

The aircraft is manufactured by:

Flight Design GmbH

Sielminger Str. 51

70771 L.-Echterdingen

Germany

Web: www.flightdesign.com

e-mail: [email protected]

01-00.5 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

01-00.6 General Safety Information

Consider the following warnings to avoid unnecessary risks while you carry out maintenance of the aircraft:

▲Warning: Only the personnel with adequate qualification may carry out an inspection and maintenance work.

▲Warning: You shall carry out inspection and maintenance in accordance with respective national safety requirements.

▲Warning: Before you begin any work, you shall read and understand all relevant sections of this AMM. In case of any doubt or missing information you shall first contact the manufacturer for advice.

▲Warning: Consider the safety notes in this supplement as unconditional.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

01-00-2

01-00.7 Source to Purchase Parts

Spare parts can be ordered directly with the airplane manufacturer:

Flight Design GmbH

Sielminger Str. 51

70771 L.-Echterdingen

Germany

Web: www.flightdesign.com

e-mail: [email protected]

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.

01-00.8 List of Disposable Replacement Parts

Chapter

71-00.3.3 Air filter

74 Spark plugs

Item Overhaul Replacement Time

no no

1 year

50h no no

50h

200 h

01-00.9 Recommended Torque Values

Refer to basic AMM.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

01-00-3

CHAPTER 02 – ORGANIZATION AND HANDLING OF THE

SUPPLEMENT

Contents

Structure

02-00.1.1 Chapter

02-00.1.2 Page Numbering System

02-00.1.3 Figures

02-00.1.4 Warnings, Cautions and Notes

02-00.1.5 Abbreviations

Handling

02-00.2.1 Record of Revisions

02-00.2.2 List of Effective Sections

This AMM Supplement is structured using the ATA 100 structure for system / subsystem as guideline. This is reflected in the main header of each Chapter, Section and in the section numbers. Four digits are used that represent:

25-60

System-Subsystem

Chapter No.-Section No.

The contents of chapter and subchapter are structured similarly, so that you can find required information quickly. For your convenience each chapter contains its own table of contents.

Pages are numbered using a combination of the chapter and section number, followed by the page number, each separated with a dash ”-“.

02-00.1.3 Figures

Figures are numbered using a combination of the chapter and section number, followed by a sequential number that starts with 1 for each subsystem, each separated with a dash ”-“.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

02-00-1

Please pay attention to the following symbols which are used throughout this document to emphasize certain information:

▲Warning: Used to identify an instruction which if not followed may cause serious injury or even death.

■ Caution: Used to identify an instruction which if not followed may damage the aircraft severely or lead to the warranty suspension.

“Shall”, “will”, “should” and “may”:

The words “shall” or “will” are used to express a mandatory requirement or instruction. The word “should” is used to express non-mandatory provisions that are nevertheless highly recommended. The word “may” is used to express permissible provisions.

02-00.1.5 Abbreviations

The table below contains the abbreviations used in this AMM.

Meaning Abbreviation

AMM

FAA

LSA

POH

TBO

TBR

Airplane Maintenance Manual

Federal Aviation Administration

Light Sport Aircraft

Pilot’s Operating Handbook

Time Between Overhaul

Time Between Replacement

02-00.2.1 Record of Revisions

This supplement has a Record of Revisions. Use the Record of Revisions to show when changes were included in this supplement.

02-00.2.2 List of Effective Sections

This supplement has a List of Effective Sections. The List of Effective Sections shows you the number and effective date of each section of this supplement. This system implies that revisions are always done section wise; when information in one section changes, all pages of that section get changed.

Use the Feedback Template provided by the basic AMM to inform manufacturer about difficulties experienced during maintenance.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

02-00-2

CHAPTER 04 – AIRWORTHINESS LIMITATIONS

Contents

04-00.1 General

04-00.4 Life Limited Components

04-00.1 General

This Section shows the mandatory limitations established by the airframe manufacturer.

These limitations shall be obeyed by the maintenance personnel.

In addition to this, the manufacturer recommends you to comply with the maintenance time limits and to work with the maintenance checklists (refer to CHAPTER 05 – TIME LIMITS

AND MAINTENANCE CHECK).

In any case you must comply with the national maintenance requirements.

Limitations provided in the basic aircraft AMM remain valid.

Limitations provided in the basic aircraft AMM remain valid.

04-00.4 Life Limited Components

Chapter

71-00.3.2 Engine shock mount

Item Overhaul Replacement Time

no 2000 h or with engine replacement, whichever comes first

28-00

75-00

79-00

71-00.3.3

All engine rubber parts, such as:

 All rubber hoses of the cooling system

 All rubber hoses of the fuel system (incl. Teflon hoses, fuel pump and insulating flange if this is fixed with fuel hoses)

 All rubber hoses of the lubrication

 Connecting hose of the air intake system no

5 years

ROTAX

®

912iS (1) 2000h or 15 years whichever comes first

(1) Refer to latest issues of BRPROTAX

®

concerning the TBO, i.e. Service Bulletins, Service information, and to the ROTAX

®

Aircraft Engines Maintenance Manual for ROTAX

®

Engine Type 912 Series.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

04-00-1

CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK

Contents

05-00.1 General

05-00.2 Levels of Certification

SECTION 05-10 – TIME LIMITS

05-10.1 General

05-10.2

05-10.3

05-10.3.1

05-10.3.2

Scheduled Maintenance Time Limits

Component Time Limits

Time between Overhaul

Time between Replacement

SECTION 05-20 – SCHEDULED MAINTENANCE CHECK

05-20.1 General

05-20.2.1 Identification

Records

05-20.2.3 Run-Up

05-20.2.4 Post Run-Up, Pre-inspection and Preparations

System

05-20.2.6 Fuselage

05-20.2.7 Wings

05-20.2.8 Empennage

Gear

05-20.2.10 Cabin and Baggage Compartment

05-20.2.11 Return to Service

Check

05-20.3.1 General

Check

Check

SECTION 05-30 – UNSCHEDULED MAINTENANCE CHECK

05-00.1 General

This chapter contains time limits and maintenance checklists for the CTLS-LSA. We highly recommend you to comply with the maintenance time limits and to work with the maintenance checklists.

Levels of certification used in this manual are:

Pilot/Owner: The owner of an aircraft who holds a pilot certificate but who has not received any 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.



Approval Ref.:

Document Title Document No. Revision

AF 0480 0011 00

Date

05-Aug-12


Section

05-00-1

A&P:

An Airframe and Powerplant mechanic as defined by 14 CFR Part 65 in the U.S. or equivalent certification in other countries.

● Note:

● 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.

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.

For and questions or comments regarding maintenance procedures or minimum levels of certification, email Flight Design at [email protected]

.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-00-2

SECTION 05-10 – TIME LIMITS

05-10.1 General

All scheduled maintenance checks have time limits. You shall do the scheduled maintenance within the time limits.

05-10.2 Scheduled Maintenance Time Limits

The table below contains scheduled maintenance time limits recommended by the manufacturer. Different tolerances may apply due to national regulations, depending from the type of operation.

Scheduled Maintenance

100 hour check *

Task at these times

At 100 hours since new and every 100 hour interval. Do the work of 100 hour check.

Perform all engine 100 hour inspection items per engine manufacturer maintenance manual

Perform all propeller 100 hour inspection items per propeller manufacturer maintenance manual

Tolerance

±10 hours

25 hour check *

“Other times” checks

Annual check

At 25 hours since new or at 25 hours after change or overhaul of engine and/or propeller.

Perform all engine 100 hour inspection items per engine manufacturer maintenance manual

Perform all propeller 25 hour inspection items per propeller manufacturer maintenance manual

At specified time interval from checklist since new and every specified time interval.

Do the work for “other times” interval specified in checklist

At 12 month from new and every 12 month interval.

Do the work of annual check.

±5 hours

±10 hours

±30 days

* All of the (engine) maintenance intervals relate to the number of operating hours of the engine, whereas all time during the engine is running is counted towards the total number of operating hours, irrespective of load factor of the engine, such as idling or take-off power.

05-10.3 Component Time Limits

05-10.3.1 Time between Overhaul

The airplane components that shall be overhauled on expiration of scheduled time limits are listed in Section 04-00.4.

05-10.3.2 Time between Replacement

The airplane components that shall be replaced on expiration of scheduled time limits are listed in Section 04-00.4.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-10-1

SECTION 05-20 – SCHEDULED MAINTENANCE CHECK

05-20.1 General

Perform the scheduled maintenance checks in this Section at the intervals (operating hours and calendar time) marked in SECTION 05-20 with a “” or at the time specified.

● Note:

● Note:

● Note:

Only persons authorized by the National Aviation Authority of the country where the airplane is registered may perform these checks.

The inspection level for each item is a general visual inspection unless differently specified.

The Maintenance Manual of the ROTAX

®

912 iS engine contains the periodic maintenance schedule for this engine. We highly recommend you to perform the 100-hour checks of the engine at the same time with the airframe inspection.

05-20.2 Scheduled Maintenance Checklist CTLS-LSA

05-20.2.1 Identification

Name of

Pilot/Owner

Call-sign

Aircraft S/N

Engine S/N

Propeller S/N

Maintenance

Organization

Hours since Last

Scheduled

Inspection

Date of Inspection

F-___-___-___

Operating Hours

Operating Hours

TTSN/ TTSO

Operating Hours

TTSN/ TTSO

Name of Inspector

Type of Last

Scheduled

Inspection





100h annual other:______________

Type of Inspection

 100h annual

 other:______________

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-20-1

This chapter of AMM is not affected by this Supplement

05-20.2.3 Run-Up

▲Warning: Run-up shall be performed before any inspection.

▲Warning: Run-up shall continue until all temperatures are acceptable for take-off.

Inspection and/or Required Maintenance

Checklist

Minimum

Level of

Certification

Initials /

Remarks

Engine and engine compartment

Clean for leakage check

Run up of engine: Conduct per following checklist, fill pre-inspection values only:









Pilot/Owner

Pilot/Owner

Systems

Engine oil. Check the level of oil and follow the Operator’s

Manual for all versions of ROTAX

®

912 iS or SECTION 12-10.

Pre-inspection Post-inspection

 

Brakes and parking brake. Check for proper operation

Starter. Smooth operation, starting properties









Oil pressure. 3…5 bar / 44…73 PSI bar/PSI bar/PSI

Engine Instruments. Check engine parameters

Ignition ground test. (See Operator’s Manual for ROTAX

®

912 iS)









Oil temperature. 90…110°C /190…230°C

°C/

F °C/F

▲Warning: Ensure that cylinder head temperature (CHT) and oil temperature are within limits.

Cabin heat

Idle RPM. Tachometer should read 1400 RPM

Engine full power RPM. Tachometer should read 4900 to

5000RPM

Ignition check. Set RPM to 4000.

Turn “OFF” LANE selector switch A. Record rpm drop. Must not be more than 180.

Turn “ON” LANE selector switch A.

Turn “OFF” LANE selector switch B. Record rpm drop. Must not be more than 180.

Turn “ON” LANE selector switch B.

 

RPM RPM

RPM RPM

RPM

RPM

RPM

RPM

Directional stability of nose gear

 

▲Warning: Allow engine to cool down to 149°C (300°F) (CHT) before shutdown. Shut down the engine, set the ignition switch and the master switch to the off position. Remove ignition key from the aircraft.

Check for fuel and exhaust odors in cabin

Check for fuel stains on floor





Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12






Section

05-20-2


Checklist

Check fuel valve off function

Notes:

Minimum

Level of

Certification



Initials /

Remarks



05-20.2.4 Post Run-Up, Pre-inspection and Preparations


Checklist

Minimum

Level of

Certification

Airframe, engine, propeller

Perform a walk around to detect damage, fluid leaks or other abnormalities,

Check visual the installation geometry between fuselage/ wing/ empennage and engine/ propeller/ cowling

Check leveling of aircraft on ground.

Engine cowling

Remove engine cowling.

Refer to Section 71-00.3.1

Spinner

Remove spinner as defined in the basic aircraft

AMM

Make record of all malfunctions and abnormalities

 

Pilot/Owner

 

Pilot/Owner









Pilot/Owner

Pilot/Owner

Initials /

Remarks


Checklist

Minimum

Level of

Certification

Cleaning. Clean the engine as required in the

Maintenance Manual for ROTAX

912 Series.

®

Engine Type

Engine. Conduct 100 hrs inspection as per

Maintenance Manual for

ROTAX

®

Engine Type 912 iS Series.









Pilot/Owner

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Initials /

Remarks

Section

05-20-3


Checklist

Minimum

Level of

Certification

Initials /

Remarks



ROTAX

®




ROTAX

®


Engine cowling. Inspect for cracks, chafing, heat damage, delamination, exhaust or fluid leaks, condition of fastening system, and condition of paint.

Engine control panel. Check for full range of travel, stop adjustment and required friction.

Remove cover and check levers for damage, cracks, corrosion. Check cables for wear and security.

Refer to Section 76-00.3.1.3

Cooling air ducts, engine baffling and cylinder

cooling fins. Check for obstructions, cracks, wear and general condition. Check for signs of abnormal temperatures.

Refer to CHAPTER 75

Oil and coolant radiator. Check for obstructions, leaks and security of attachment. If necessary clean cooling ribs.


Coolant hoses and lines. Check for damage, leakage, hardening from heat, porosity, for loose connections and secure attachments. Check routing for kinks and restricted elbows. Check fire protection shielding.

Refer to CHAPTER 75

Oil Lines. Inspect for damage, leakage, hardening from heat, porosity, security of connections and attachments. Verify routing for kinks or restricted elbows. Check fire protection shielding.

Refer to CHAPTER 79

Oil tank vent line. Check for proper routing, for obstructions and clear passage

Refer to CHAPTER 79

Fuel lines. Check for damage, leakage, hardening from heat, porosity, secure connections and attachments. Verify routing for kinks or restricted elbows. Steel fuel lines if applicable additionally check for cracks and for scuffing marks. Check fire protection shielding on the all fuel lines in engine and pilot compartment.

































200 hrs

600 hrs

A&P

A&P

Pilot/Owner

RLSA-M

Pilot/Owner

Pilot/Owner

RLSA-M

RLSA-M

Pilot/Owner

RLSA-M

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-20-4


Checklist

Minimum

Level of

Certification

Refer to Section 28-00.3

Gascolator. Open the gascolator, remove the filter and check for cleanliness. Clean filter and reinstall. Check gascolator drain valve for correct function and leakage.


Fuel shut off valve. Check for security of attachment and signs of fuel leaks. Check that valve engages noticeable into the position ON/OFF.


Fuel Flow Rate. Check the value of fuel flow rate as defined in the basic aircraft AMM.

Fuel flow rate: L 40 /____ / (l/h)

R 40 /____/ (l/h).

Fuel contamination test. Take fuel samples from both wings. Inspect for contamination, as defined in the basic aircraft AMM.

Induction system. Check connection of manifolds between NACA-Inlet, Air filter box and carburetors for damage, security of attachments and condition.

Inspect connected air hoses for condition and leakage.


Air filter box. Check that the sealing surfaces are in good condition and clean. Inspect and clean filter. Replace if necessary. Clean air filter box inside. Check the drain hole at the bottom of the box for obstructions or blockage.


Cabin heater. Check heat shroud and heater attachments. Check the manifold for holes and attachments. Check the heater activation system for proper operation. Check activation system for wear and security of attachments, as defined in the basic aircraft AMM

Exhaust system. Checks attachment screws and springs for security and fit. Inspect system for damage and missing parts. Visual inspection of muffler, exhaust pipes and mounting flanges for cracks, corrosion and leakage.

Refer to CHAPTER 78

Exhaust muffler. Remove heat shroud from muffler and inspect muffler for condition, corrosion and leakage

 

Pilot/Owner

 

RLSA-M

 

RLSA-M

 

Pilot/Owner

 

Pilot/Owner

 

Pilot/Owner



Pilot/Owner

 

RLSA-M

200h RLSA-M

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Initials /

Remarks

Section

05-20-5


Checklist

Minimum

Level of

Certification

Initials /

Remarks

Refer to CHAPTER 78

▲Warning: Failure to inspect Muffler for leaks could result in Carbon monoxide entering the cabin, leading to serious injury or death!

Firewall. Inspect for cracks, delamination, buckling, and other signs of damage. Inspect all items attached to firewall for security.

Inspect fire protection coat for condition, signs of overheating and full coverage of firewall.

Engine mount. Lift up the nose landing gear off of the ground and inspect for deformation, cracks, corrosion, damage from heat, loose hardware, chafing by cables, wires, hoses, etc., and make sure that any flexible item is secured to the engine mount. Check mounting bolts for condition and visual signs for loss of torque. If necessary check correct torque value (see 200h).


Engine mount. Check mounting bolts for condition and correct values.

At engine (4 bolts M10): 35 Nm

At shock mounts (4 bolts M10): 35 Nm

At firewall (6 bolts M8): 22.5 Nm

Replace safety wire where necessary


Engine shock mounts. Inspect for porosity, cuts, damage and deformations


Battery attachment. Inspect for security of mounting and condition as defined in the basic aircraft AMM. Ensure that the vent holes are clean.

Starter. Check security of attachment and electrical connections, as defined in the basic aircraft AMM.

Electrical wiring system. Verify the complete electrical wiring system for security, damage, wear and secure fit. Check all cable connections for tight fit, good contact, corrosion and condition.

Other engine external accessories. Inspect screws and nuts of all other external engine parts and accessories for tight fit.

Foreign objects. Check the engine compartment for foreign objects.

































Pilot/Owner

200h RLSA-M

RLSA-M

Pilot/Owner

RLSA-M

RLSA-M

Pilot/Owner

Pilot/Owner

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-20-6

05-20.2.6 Return Service


Checklist

Minimum

Level of

Certification

Initials /

Remarks

Engine Compartment. Make sure that engine compartment is free of any tools, parts, and foreign objects. Reinstall all access panels, fairings, etc., which were removed for the inspection.

Engine. Check the presence of the oil in the oil tank, cooling liquid in the expansion tank. Make sure that the coolant level in the overflow bottle is between min and max marks as required by the

Operator’s Manual for all versions of ROTAX tools, rags, and any other foreign objects.

®

912 iS. Check that the engine compartment is free of

Engine. Run the engine for no more than two minutes at 1400 to 1800 RPM. After shutdown, check for the oil filter leaks, and any other components removed during this inspection. Install the cowlings, if there are no leaks detected.

Engine. Warm up the engine at 2000 to 2500 RPM.

Check all aircraft systems to ensure proper operation. During the engine warming, operate the engine systems at appropriate engine speeds and complete all checks listed on the Run-up checklist; fill data to the post-inspection column.

Check the wheel brakes and parking brake for functioning.

Airworthiness Directives. Verify all airworthiness directives, Service Bulletins, service information complied with.

Aircraft records. Input all necessary entries in the logbooks and any other required records. Service time Records, Equipment list and weight and balance Records – update, if necessary

























Pilot/Owner

Pilot/Owner

Pilot/Owner

Pilot/Owner

Pilot/Owner

RLSA-M

All service items required by Service Notifications, Service Bulletins, Safety Alerts and Airworthiness

Directives and all prescribed scheduled maintenance checks are successfully accomplished. The aircraft is airworthy and meets the condition specified in the aircraft data sheet.

Service station: Next inspection when ________hours of operation has been reached.

Place, Date

Name, signature of mechanic Name, signature of inspector stamp

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-20-7

05-20.3.1 General

The flight-line checks include the pre-flight and post-flight checks. Do these checks each day the airplane is used.

Perform all Preflight Inspection items as defined in the aircraft POH and POH

Supplement(s) before the first flight of the day to make sure that the general condition of the airplane and of the engine is good. It is important for flight safety. Look in the airplane log-book for problems before doing the pre-flight check.

▲Warning: Do all the steps of the pre-flight check carefully. Accidents can occur if the pre-flight check is not done correctly.

Re-do all Preflight Inspection items as defined in the aircraft POH and POH Supplement(s) after the last flight of the day.

You shall also:

 Refuel the airplane (Section 12-10.2.1).

 Record in the log book each problem found in flight and during post-flight check.

 Park the airplane.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-20-8

SECTION 05-30 – UNSCHEDULED MAINTENANCE CHECK

Please contact the aircraft manufacturer for further instructions.

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

05-30-1

CHAPTER 11 – PLACARDS AND MARKINGS

Contents

11-00.1 General

11-00.2 Placards and Markings

11-00.1 General

This chapter provides you with information about exterior and interior placards and markings.

11-00.2 Placards and Markings

The aircraft is equipped with the following markings and placards:

Item Location

Fuel Type and

Quantity

Adjacent to each fuel tank filler cap

Header Tank Volume 6 l (1.6 US.gal),

4 l (1.1 US.gal) usable

On the header tank left side

Document Title



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

11-00-1

SECTION 12-10 – REPLENISHING

12-10.1 General

This section provides instructions concerning replenishing procedures.

12-10.2.1 Refueling and Defueling

Fuel content: 136 l (36) total, distributed to:

- 2 wing tanks each with 65 l (17.2 US.gal)

- one header tank with 6 l (1.6 US.gal).

Maximum Usable fuel: 130 l (34.3) total, provided by:

- 2 wing tanks each with 63 l (16.7 US.gal)

- one header tank with 4 l (1.1 US.gal).

Fuel specification:

● Note:

MOGAS EN228 Super;

MOGAS EN228 Super Plus;

AVGAS 100 LL (ASTM D910).

The header tank has no separate filler opening. The header tank automatically fills when the selected wing tank contains fuel.

12-10.2.1.1 Type of Maintenance

Line

Pilot/Owner

12-10.2.1.3 Procedure

A. Recommended Special Tools and Parts

Item Quantity Unit

None

B. Refueling

Reference

1

Step

2

3

4

5

Action

Turn the engine off.

Set parking brake

Remove the filler cap situated on the upper surface of wing skin.

Fill the fuel tank with fuel

Install the fuel filler cap

Do steps 3-5 for the other wing 6

C. Defueling

1

2

Step

Turn the engine off.

Set parking brake

Action Reference



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-1

3

Step

4

5

Action

Put a container below the gascolator drain valve.

Open the gascolator drain valve. Drain all accessible fuel from the tanks.

Close the gascolator drain valve.

12-10.2.2 Fuel Contamination Test


Line

Reference

Pilot/Owner

12-10.2.2.3 Procedure


Item

Transparent fuel tester

B. Fuel Contamination Test

Do this test each day you operate the airplane.

Quantity

1

1

Step

2

3

4

5

6

7

Action

Put the fuel tester under the header tank drain valve.

Open the drain valve.

When the container is half full, close the drain valve.

Let the fuel in the glass container stand for 1minute.

Examine the fuel. Look for small drops of water in the bottom of glass container.

Look for small particles of solid material.

Repeat steps 1 – 5 for the drain valve of the gascolator.

Test is passed when no contamination (drops of water, particles or similar) is found.

C. Troubleshooting.

If you find any contamination of the fuel you must do the following:

1

Step

2

3

4

5

6

Action

Repeat the fuel contamination test.

If you still find contamination after three tests, drain the fuel tank.

When contaminations other than water had been detected, clean filter mesh at gascolator.

When contaminations other than water had been detected and filter mesh at

Gascolator shows noticeable clogging, exchange fine fuel filter in engine compartment.

Flush the tank and fill with clean fuel.

Re-do contamination test after re-fuelling

Unit

pcs

Reference

Reference

12-10.2.1

28-00.3.1

28-00.3.1

12-10.2.1



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-2

12-10.2.3 Fuel Flow Rate Check


Line

Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher.

12-10.2.3.3 Procedure


Item

Transparent container

Measuring jug, fuel and ethanol resistant, min. 4 l (1 US.gal).

Alternatively, transparent container as above with calibrated volume markings

Quantity

1

Unit

pcs

1 pcs

Marking pen that will write on the transparent container 1 pcs

B. Fuel Flow Rate Check

Check the fuel flow per minute of each tank through the gascolator exactly and note and compare with the previous fuel flow rate. If there is a drop more than 5%, then check full system (bows in fuel lines) and if still a difference, check the fuel filters in the wings.

1

2

Step

3

4

6

7

8

9

10

Action

Set the plane on the prepared platform.

Set a fuselage on horizon level, using supports under the main wheels.

Fill fuel tank in the left wing with minimum 5 liters of fuel. Open the gascolator drain valve. Fuel will drain by gravity.

When fuel does not drain automatically, close the drain valve and then push the tail of the aircraft down and hold it in this position for a minute. This will start the fuel flow. Re-open the drain valve again.

Let fuel flow for 3 minutes. Apply markings of the fuel level on the container after each minute.

Close drain valve after exactly 3 minutes

Use measure jug to measure the drained volume per minute.

Required minimum flow rate is 40 liter (10.6 US.gal) per hour. This is equal to

667 ml (0.176 US.gal/min) per minute

Drain all fuel from the left wings tank.

Repeat procedure for the right wing tank.

Reference

12-10.2.1

C. Troubleshooting.

If fuel flow rate on either or both sides is less than 40 l / hour, it is necessary to check:

1

Step

2

3

Action

Check fuel hoses for absence of kinks. Fix, when found.

Check gascolator filter mesh for contamination and clean.

Repeat the fuel flow test.

Reference

28-00.3.1



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-3

CHAPTER 28 – FUEL SYSTEM

Contents

28-00.1 General

28-00.2 Description

Practices

28-00.3.1 Fuel System Inspections

28-00.3.2 Fuel

28-00.3.3 Fuel Hoses and Lines Replacement

28-00.1 General

This chapter provides description of the Fuel System.

28-00.2 Description

The fuel system consists of:

- integrated in to each wing fuel tank with capacity of 65 l (17.2 US.gal) with sight gauges at the root rib

- Header tank in the rear fuselage with capacity of 6 l (1.6 US.gal) with fuel level warning sensor

- fuel tank selector valve

- separate fuel shut-off valve

- electrical fuel pump set

- gascolator with filter screen

- fine fuel filter

- fuel system drainage

- fuel tank venting

- two fuel flow meters (optional)

The principal scheme of fuel system is shown on Fig 28-00.1.

A fuel tank is integrated into the leading edge of each wing. The fuel tanks are each divided into two sections by an anti-sloshing rib (Fig. 28-00-2). Fuel is filled into the outer section via a fuel filler opening on the upper side of each wing. Each tank outlet has a coarse screen which can be removed via a maintenance plate in the root rib for visual inspection and cleaning. Fuel is fed by gravity via two fuel lines to the fuel selector. After fuel selector, fuel flows to the header tank. The header tank volume is selected so that even with virtually empty tanks, enough fuel is available in a sideslip to ensure engine power for landing. The header tank has a drainable sump. The fuel system must be drained at this point before the first flight of the day and after filling up with fuel.

The fuel is fed from the header tank to the gascolator which has a fine filter mesh included.

The gascolator is the lowest point in the fuel system and has a drain valve. The fuel system must be drained at this point before the first flight of the day and after filling up with fuel. The fuel flows from the gascolator to the electrical fuel pumps, placed under left baggage compartment. The fuel shutoff valve is located directly before the line passes through the fire wall.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-1

From shutoff valve fuel flows through a fine filter to the injection lines, the injection valves and the fuel pressure regulator. The fuel pressure regulator keeps injection pressure at the desired level and allows surplus fuel to feed back to the header tank. The back-flow line is also blocked when the fuel shut-off valve is closed.

The Fuel System is presented schematically on the following diagram (Fig. 28-00-1).

Fig. 28-00-1. Scheme of Fuel System



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-2

Fig. 28-00-2

To open the fuel filler cap, the lever in the cap must be raised and turned 90° anticlockwise. The cap can then be removed. The cap is properly shut when the lever is pressed down into position (Fig. 28-00-3).

Incorrect position Correct position

Fig. 28-00-3

Fuel flows via a flapper valve into the inner section of the fuel tank inboard of the antisloshing rib. The flapper does not completely seal the inner tank. But it does greatly restrict the return flow of fuel into the outer chamber when one wing is low (sideslip).

A special epoxy covering is applied to the inner surface of the fuel tank. The covering is resistant to fuel and ethanol and ensures continued leak resistance of the tank.

The outlet with integrated coarse screen is installed in the wing root rib. The outlet can be removed via a maintenance plate in the root rib for visual inspection and cleaning. The maintenance plate is provided with a sight gauge. When wings attached to the fuselage the sight gauges are visible to the occupants (Fig. 28-00-4).



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-3

Fig. 28-00-4

The tanks are vented via tubes in the outer tank sections, the air coming from NACA inlets on the outer side of each of 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.

Fig. 28-00-5

The header tank has venting line routed to the left wing tank. The vent tube is led through the tank along the upper wing skin to the highest point of fuel tank. Due to this, overflow fuel from the header tank goes to the left wing tank and cannot be spilled (Fig. 28-00-5).



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-4

Fig. 28-00-6

Fuel selector is placed behind occupants at the fuel selector box (Fig. 28-00-7). The fuel selector normal operating position is “both”, a single tank is only selected temporarily to correct a possible fuel imbalance. Selection of a single tank is announced by the EMS to remind the pilot to go back to “both”. The selector valve does not allow to shut off the fuel flow.

Fig. 28-00-7

The fuel pumps block and gascolator are located in left side of luggage compartment and covered with composite box with hatch for inspection and maintenance.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-5

Fig. 28-00-8

The fuel shutoff valve is located after Fuel pumps, on the tunnel. This valve closes both, feed line and back flow line and therefore completely separates the engine compartment.

As an option two fuel flow transducers can be placed after the shutoff valve. Fuel consumption metering is achieved by the difference between the feed line and the back flow line fuel flow. If fuel the flow transducers are not set, the fuel consumption is calculated by the engine control unit (ECU).

From the shutoff valve fuel flows through the very fine fuel filter to the injection lines, fuel pressure sensor, the injection valves and the fuel pressure regulator. The fuel pressure regulator feeds any surplus fuel back to the header tank (Fig. 28-00-8).

Fig. 28-00-9



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-6

Fig. 28-00-10



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-7

28-00.3.1 Fuel System Inspections


Line

Repairman, Light Sport Aircraft-Maintenance (RLSA-M) or higher

28-00.3.1.3 Procedure



None

B. Fuel Filter Inspection

Step Reference

1

2

3

4

5

6

Action

Inspect the fuel filter if the fuel pressure is less than normal or a sharp drop off in pressure is observed.

Inspect all fuel lines for damage, leakages, connections securing. Verify lines routing for kinks or restricted elbows.

Check fuel hoses fire sleeves in engine compartment for hardening from heat, porosity, connections securing.

Move handle to position ON to open fuel shutoff valve.

Drain rest of the fuel from fuel lines through gascolator to sufficient container. To drain the fuel push to the gascolator drain valve and turn it.

Loose four screwed clamps, and remove fireproof covering

Clamps

Unscrew fitting nuts and detach fuel lines from the filter. Remove filter. When necessary – replace filter. Fitting nuts

7

8

9

10

Install fuel filter in reverse order of step 8.

Fill fuel to fuel system and operate fuel pumps. Check system to be free from leakage.

Complete installation in reverse order of Step 7, above.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-8

C. Gascolator Inspection

1 Drain all fuel from the system.

Remove lock wire from Gascolator and remove gascolator bowl.

2

3

4

5 Assemble gascolator in reverse order.

D Shut off valve Inspection

1

Clean gascolator bowl and inspect for damage, cracks and scuffing marks.

Clean gascolator filter screen.

2

Remove lower instrument panel.

Inspect shut off valve attachment and for leakage. Check that valve engages noticeable into the position ON/OFF. Ensure that both valves open / close simultaneously.

E Fuel Tanks Inspection

1

2

3

4

5

6

7

8

9

11

Drain all fuel from the system.

Remove the wings as per instructions in the basic AMM.

Inspect external surfaces of fuel tank for leakages and foreign objects.

Inspect sight gauges for security and presence of fuel leakage, and readable indication. Replace gauges if necessary

Inspect Fuel filler caps for proper locking and leakage.

Check that the placards are present and readable.

Unscrew 6 nuts M6, securing the cap plate at the root rib. Inspect inner surfaces of fuel tanks, condition of sealant and inner structure. Clean if required.

Inspect fuel flap in slosh rib for proper functioning and attachment.

Inspect the strainer at the fuel tank outlet for contamination through opening in root rib. Clean if required.

Check fuel vent lines and connections for leakage and blockage. Blow through if required.

12

13

Remove all remains of the old Hylomar sealant and of the old rubber seal ring

KF 2800 0009 from the cap plate and from the flange at the wing.

Apply the Hylomar Universal Blue onto the surfaces of the root rib ring, of the cap plate, and onto both contact surfaces of the rubber seal ring.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-9

14

15

16

17

Install the rubber seal ring and press it to the root rib ring.

Install the cap plate and press it.

Install the washers and the self-locking nuts M6.

Do pre-tightening of the nuts, in a sequence shown on picture below, thus the cap plate is not askew.

18

20

21

22

23

24

19

Tighten the nuts in the following sequence:

 Apply the tightening torque 2 Nm for each nut.



Carefully remove excessive Hylomar Universal Blue.

When the Hylomar Universal Blue is fully hardened, close the fuel outlet with the suitable cap, for example – with the clamped fuel hose. Place the wing on the support so that the root rib is lower than the wing tip.

Fill the fuel tank with 30…35L (8…9 U.S. gallons) of the fuel. Check that the fuel sight gage is filled with fuel.

In 12 hours do visual inspection of the repaired area of the root rib for the fuel leaks.

Drain all fuel from the wing through the fuel outlet. Check that the fuel sight gage empties with fuel level going down.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-10

28-00.3.2 Fuel Pumps Block Removal and Installation


Line


28-00.3.2.3 Procedure



None

B. Fuel Pumps Block Removal

Step

1

Reference

12-10.2.1.

2

Action

Drain fuel through gascolator to sufficient container.

Open cover in left luggage compartment floor to gain access to the fuel system components.

Unscrew 4 nuts from support:

Nuts

3

Unscrew fitting nuts and disconnect hoses from Fuel pump.

Fitting nuts

Remove Fuel Pumps bloc.

Unscrew 4 bolts, and remove Fuel Pumps box.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-11

Fuel pumps box

Bolts

4

5

Inspect the Fuel Pumps for damage, corrosion and leakages before re-installation.

Install Fuel Pumps in reversed order

28-00.3.3 Fuel Hoses and Lines Replacement


Line

Airframe and Powerplant mechanic (A&P)

28-00.3.3.3 Procedure

For fuel lines being part of the ROTAX

®

engine, refer to the ROTAX valid for your individual engine.

®

Maintenance Manual

For all other fuel lines, contact aircraft manufacturer for further instructions.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

28-00-12

CHAPTER 71 – ENGINE

Contents

71-00.1 General

71-00.2 Description

71-00.3.1 Engine

71-00.3.2 Engine Mount Inspection

71-00.3.3 Air Induction Inspection

71-00.3.6

Replacement

Replacement

Other Engine Maintenance

71-00.1 General

This chapter provides description of the engine systems.


The engine of the CTLS-LSA is a standard ROTAX

®

912 iS or iSc engine.

● Note: For simplicity reasons this manual will refer to the ASTM compliant engine version Rotax 912 iS. Any instructions provided in reference to this engine automatically applies as well to the otherwise technically identical Type Certified engine version Rotax 912 iSc, unless explicitly noted otherwise.

It is a horizontally opposed, four cylinder, fuel injected four stroke engine with central camshaft pushrod driven overhead valves, liquid-cooled cylinder heads and a ram air cooling of the cylinders, dry sump, pump-fed lubrication system with integrated pressure regulator. The propeller is attached to the engine by an integrated gearbox (2.43 : 1 reduction) with a mechanical shock absorber and overload clutch. It is equipped with a fully redundant electronic engine management system, including fuel injection and electronic dual characteristic ignition. The engine has an electric starter and two integrated generators, whereas one is normally used to support the engine, while the second generator powers the aircraft systems.

The engine is equipped with a closed circuit water cooling system of the cylinder heads with an expansion tank and overflow bottle.

The oil pump is driven by the camshaft. The oil system incorporates an oil cooler and a oil tank.

All details of the engine design are provided in the Operator’s Manual OM-912i provided by the engine manufacturer for the installed engine.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-1

71-00.3.1 Engine Cowlings Removal

The upper and lower cowling cover the engine compartment. The cowlings are connected together and attached to the fuselage. The cowlings are connected with quick fasteners.

The upper cowling provides an inspection hatch for access to oil and coolant tanks.

The lower cowling provides air-inlets for engine cooling, air induction, cabin heat and mounting position for the optional landing light.

Fig. Item Part Name

1 Cowling, Engine, Upper

2 Cowling, Engine, Lower

Fig. 71-00-1

71-00-1

5

6

Button TENAX 01

Button TENAX 04

Torque Reference

KF71100100

KF71100203

KF71100112

C9997732I

C9997541A

C9997541B

C9996903Z

C9996911A



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-2


Line

Pilot/Owner

71-00.3.1.3 Procedure



None

B. Engine Cowlings Removal

Step

1

Action

Place chocks on the wheels and confirm that the ignition switch is OFF

Unscrew 13 Camlock Studs 7 of upper cowling:

Press and turn with the screwdriver to quarter-turn;

Reference

71.2.1

2

Remove Camlock Studs.

3

4

5

7

Remove Upper Cowling 1.

Loosen clamp on the hose routed to the airbox.

Unscrew 6 Camlock Studs 7 of lower cowling. Remove Lower Cowling 2.

Inspect the Cowlings and Camlock Studs for damage. Replace Camlock Studs if required

Install Cowlings in reversed direction order

71-00.3.3.3



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-3

71-00.3.2 Engine Mount Inspection

The engine is attached to the primary aircraft structure by a strong steel engine mount.

The small engine mount is attached directly to engine. The small engine mount is attached to the Big Engine mount with rubber shock mounts.

Fig. 71-00-2

Fig. Item

71-00-2

Part Name

1 Big Engine Mount

2 Small Engine Mount

4 Shock Mount Washer

6 Spacer

7 Washer

8 Self-Locking Nut M10

9 Washer

10 Washer

12 Self-Locking Nut M8

14 Screw M10


KF71200100

С9997796X

C9997789L

Part of set C9997789L

KF71000009, KF71000010, KF71000011,

KF71000013

KF71000005, KF71000006, KF71000007,

KF71000008

35 Nm

C9996506

C9996337

KF71000012

C9996567

C9996259V

22.5 Nm C9996336

35 Nm

C9996570D

KF71200001, KF71200002, KF71200004,

KF71000018



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-4


Line


71-00.3.2.3 Procedure


Item

Padded support

B. Engine Mount Inspection

1

Step

2

3

4

5

6

7

Quantity

1

Unit

Pcs

Action

Remove upper and lower cowlings

Lift the forward fuselage by pushing down the tail at the narrowest part so that the Nose Wheel is at least 25 cm (10 inch) off the ground.

Insert the padded support securely just behind the firewall (under the fuselage bottom).

Inspect the Engine Mounts 1 and 2 for deformations, cracks, paint delaminating, corrosion, loose hardware, chafing by cables, wires, hoses, etc., and make sure that any flexible item is secured to the engine mount.

Inspect the rubber Shock Mounts for porosity, cuts, damage and deformations.

Inspect the presence of lock wire on engine mounting Screws M10 item 14.

Replace safety wire if necessary.

Inspect engine mounting screws for condition and tightening. Check markings of marked bolts, remove safety wire and re-torque bolts that are safety wired. Reinstall safety wire when done and where applicable.

Reference

71-00.3.1

71-00.3.3 Air Intake Inspection

Air is fed into the engine from a NACA inlet at the right side of the lower cowling, through a cylindrical air filter installed in the filter box at the lower cowling and through throttle body socket which fills airbox with sufficient airflow.

Airbox is equipped with two pressure sensors and two temperature sensors for both injection manifolds.

Air intake to fuel injectors flow through intake manifolds. This process is controlled by

ECU, and provide optimized fuel consumption.

Airbox

Clamp

Lower Cowling

Intake

Manifold

Aeroduct Hose

NACA inlet

Fig. 71-00-3. Air Intake System



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-5


Line

Pilot/Owner

71-00.3.3.3 Procedure



None

A. Air Intake System Inspection; Airfilter Removal and Installation / Exchange

Step

1

2

3

Action

Remove upper cowling

Check Aeroduct hose for damage, security of attachments and condition.

Check the Air filter installation. Inspect tightening of securing clamps.

Reference

71-00.3.1

3 Cover

Fig. 71-00-4. Air Filter installation


1 Lower cowling with dust filter box

Torque

71-00-4

Step

1

2

7 Rivet Nut M4

8 Clamp

B. Dust Filter Inspection.

Action

Loose Clamps 5 and remove Aeroduct Hose 4.

Unscrew three Screws 6 and remove Cower 3.

Reference

KF71100203

C9997191C

KC28001021

C9993188A

C9997723B

C9996159

C9996833

C9997791C



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Reference

Section

71-00-6

3

4

5

6

Check conditions of dust filter. Clean Air Filter 2 and Lower Cowling Filter Box 1.

Replace Filter if required.

Check the drain hole at the bottom of the dust filter box for obstructions or blockage.

Check incoming air line for damage, security of attachments and condition.

Install air filter in reverse order.

71-00.3.4 Starter Replacement


Line

Airframe and Powerplant mechanic (A&P).

Refer to the applicable Rotax engine maintenance manual for further task specific requirements.

71-00.3.4.3 Procedure

Refer to the maintenance manual provided by the engine manufacturer for the specific engine.

71-00.3.5 Generator Replacement


Heavy



71-00.3.5.3 Procedure


71-00.3.6 Other Engine Maintenance

This maintenance practice covers all maintenance items that affect the core engine directly, that are not otherwise defined within this AMM and that are appropriately defined within the applicable Rotax engine maintenance manual.


Heavy





Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-7

71-00.3.6.3 Procedure




Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

71-00-8

CHAPTER 73 – ENGINE FUEL AND CONTROL

Refer to the maintenance manual provided by the engine manufacturer for your engine for description and maintenance instructions on the engine-mounted portion of the fuel system.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

73-00-1

CHAPTER 74 – IGNITION

Refer to the maintenance manual provided by the engine manufacturer for your engine for description and maintenance instructions on the ignition system including spark plugs.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

74-00-1

CHAPTER 75 – COOLING

Contents

75-00.1 General

75-00.2 Description

75-00.3.1 Cooling

75-00.3.2 Cooling Hoses and Lines Replacement

75-00.1 General

This chapter provides description and information concerning maintenance of engine cooling.


The engine is provided with liquid cooling. The coupled water and oil radiators are installed in front of the engine just behind the air-inlet. The fresh air flow through the radiators enclosure and cool down coolant liquid and oil. An optional water thermostat can be included to the system to further stabilize engine temperatures.

Fig. 75-00-1 Cooling system diagram without thermostat



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

75-00-1

Fig. 75-00-2. Cooling system diagram with thermostat

From the top of the cylinder heads the coolant passes on to the expansion tank. Since the standard location of the radiator is below engine level, the expansion tank located on top of the engine allows for coolant expansion. The expansion tank is closed by a pressure cap (with excess pressure valve and return valve). As the temperature of the coolant rises, the excess pressure valve opens and the coolant will flow via a hose at atmospheric pressure to the transparent overflow bottle. When cooling down, the coolant will be sucked back into the cooling circuit. The overflow bottle is attached to the airframe structure. For cooling system employed components (radiator, extension tank, overflow bottle, thermostat (if use) and the set of connection fittings) supply together with engine by engine manufacturer. Engine manufacturer provided all requirements to cooling system parts.

Cylinder head temperatures are measured by means of temperature probes installed in cylinder heads.

Air cooling of cylinders provided by a composite cooling shroud is installed on the top of crankcase. It directs fresh air from cowling air inlet to all cylinders.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

75-00-2

Fig. 75-00-3. Cooling System



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

75-00-3

75-00.3.1 Cooling Inspection


Line

Pilot/Owner

75-00.3.1.3 Procedure



None

B. Cooling Inspection

1

Step

2

3

4

Action

Inspect connections for leaks.

Check coolant level. Replenish if required.

Inspect cylinders for dents, cracks and cooling jacket for chafing marks and burn spots. If damage observed – replace cooling jacket.

Check the securing and conditions of Cylinder Head Temperature (CHT) sensor.

Tighten sensor with torque 10Nm and secured with Loctite 221.

Reference

5

6

7

Fig. 75-00-4. Cylinder Head Temperature sensor.

Check conditions of cooling lines and connections for leaks. Check cooling lines for damage, overheating marks. Replace cooling line or clamp if required.

Inspect Expansion Tank, Pressure Cap and Overflow Bottle for damage and abnormalities.

Inspect Radiator Unit and its mounting points. Check Shock mounts conditions and connections tightening.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

75-00-4

Shock mount

8

Fig. 75-00-5. Radiators Unit mounting

Remove clamp from overflow bottle hose and disconnect the hose from nipple. Remove clamp from vent tube, and disconnect it from nipple.

Inspect overflow bottle vent line for damage and blockage. Replace if required. Drain coolant in clean container.

Connect compression pump to hose free end and provide overpressure 0.2 bar/3 psi for one hour. Check all connection places for leakages.

9 Connect and secure cooling hose in reversed direction order.

75-00.3.2 Cooling Hoses and Lines Replacement

Contact manufacturer for further instructions.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

75-00-5

CHAPTER 76 – ENGINE CONTROLS

Contents

76-00.1 General

76-00.2 Description

Practices

76-00.3.1 Throttle Box Inspection

76-00.1 General

This chapter provides description and information concerning maintenance of engine controls.


The throttle quadrant is located in the center pedestal, just behind the lower instrument panel. It can be easily operated from both seats, although it is primarily designed to be operated from the left seat, by the pilot-in-command.

Pos. Description

1 Pitch trim control button.

Fig. 76-00-1

4 Parking brake valve.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

76-00-1

Detailed view is given in Fig. 76-00-2.

Fig. 76-00-2



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

76-00-2


76-00-2

3 Grip

4 Grip

5 Bolt DIN 7991 M6x35 A2-70

6 Grip

7 Grip

8 Bolt DIN 7991 M6x30 A4

9 Countersunk rivet nut, steel, M5

10 Holder

11 Bolt DIN 912 M6x30-8.8

12 Bolt DIN 912 M4x20-8.8

13 Support

14 Angle

15 Bolt DIN 912 M4x16-8.8

16 Angle

17 Support

18 Bolt DIN 933 M4x18-8.8

19 Steel rope 7x7 1 mm

20 Bolt DIN 912 M6x70-8.8

22 Screw ISO 7380 M5x12 A2-70

23 Plate

24 Bolt DIN 931 M6x35-8.8

26 Machine screw DIN 965 M2x10-4.8

27 S2 Rocker Switch

28 Self- locking nut DIN 985-M6, regular

30 Roller


KF76000151

KF76000001

KF76000132

KF76000131

C9996219

KF32400010

KF32400012

C9996218A

C9996834

DC76000101

C9996059

C9996026

DC76000156

KC76000152

C9996025

KC76000154

KC76000105

C9996282E

С9997065B

C9996065

DC76000130

С9996161

KC76000137

C9996259B

KF32400011

C9990018D

C9990018D

C9996334

KF76000136

KF76000134



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

76-00-3

76-00.3.1 Throttle Box Inspection


Line


76-00.3.1.3 Procedure



None

B. Throttle Box Inspection (Fig. 76-00-2).

4

5

6

7

8

9

1

Step

2

3

Action

Unscrew 4 bolts that fix the covering plate (2).

Unscrew bolt M6 (5) that holds the grips (3, 4) of the throttle lever (21).

Remove the grips (3, 4).

Unscrew bolt M6 (8) that holds the grips (6, 7) of the brake lever (25).

Remove the grips (6, 7).

Remove the covering plate (2).

Inspect the throttle cables/ropes for integrity.

Inspect the control levers support (10) for signs of wear.

Check control levers for smooth operation without play or undue friction.

When necessary adjust the friction in levers support by nuts (A)

Reference

10



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

76-00-4

CHAPTER 77 – ENGINE INDICATING

For maintenance instructions regarding the engine indicating system contact the aircraft manufacturer.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

77-00-1

CHAPTER 78 – EXHAUST

Contents

78-00.1 General

78-00.2 Description

78-00.3.1

78-00.3.2

Exhaust Muffler and Pipes Removal

Exhaust Muffler and Pipes Inspection

78-00.1 General

This chapter provides description and information concerning maintenance of engine exhaust.


The powerplant exhaust system consists of the muffler and exhaust pipes. The exhaust gases from the cylinders go to the muffler via the exhaust elbows. The muffler has an exhaust pipe which directs the exhaust gases outside the engine compartment. The exhaust elbows are bolted directly to the cylinders with lock nuts. The muffler and exhaust elbow connections use ball joints and springs.

Fig. 78-00-1. Exhaust System



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

78-00-1


1 Forward exhaust pipe, right

2 Rear exhaust pipe, right

3 Forward exhaust pipe, left

78-00-1 4 Rear exhaust pipe, left

5 Muffler

6 Spring

7 Nut


KF78000010

KF78000020

KF78000030

KF78000040

KF78000050

Spring

78-00.3.1 Exhaust Muffler Removal


Line


4

5

78-00.3.1.3 Procedure



None

B. Exhaust Muffler and Pipes Removal

1

Step

2

Action

Cut the safety wire, disconnect Springs (6).

Disconnect the cabin heat tube from the heating shroud flange as per instructions in the basic AMM.

Reference

Inspect muffler and heating shroud for cracks, corrosion and leakages.

Mount and secure Muffler in reverse order.

78-00.3.2 Exhaust Muffler and Pipes Inspection


Line


78-00.3.2.3 Procedure



None



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

78-00-2

B. Exhaust Muffler and Pipes Inspection

3

4

5

6

1

2

Step Action

Inspect exhaust system for damage and missing parts.

Checks attachment Nuts 7 and Springs 6 for securing and fit.

Inspect exhaust pipes and mounting flanges for cracks, corrosion and leakages.

Remove heating shroud from Muffler as per instructions in the basic AMM.

Inspect muffler for cracks, corrosion and leakages.

Mount and secure Muffler in reverse order.

Reference



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

78-00-3

CHAPTER 79 – OIL SYSTEM

Contents

79-00.1 General

79-00.2 Description

79-00.3.1 Oil

79-00.3.2 Oil Hoses and Lines Replacement

79-00.1 General

This chapter provides description and information concerning maintenance of engine oil system.


The oil system is available in two variants:

 with oil thermostat;

 without oil thermostat.

Configuration of oil system with oil thermostat installed is shown in Fig. 79-00-1.

Configuration of oil system without oil thermostat is shown in Fig. 79-00-2.

Both oil system configurations make use of the following components:

Fig. 79-00-1. Oil System diagram (with thermostat)



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

79-00-1

Fig. 79-00-2. Oil System diagram


1 Engine ROTAX® 912 iS

79-00-1

79-00-2


C9997789Z/C9997791Y

C9993515J

C9997793R

C9997793Y

C9997791I

KF79000050

C9997792D

C9993184G

C9997798O

C9997793X

8 Fuel hose (vent line)

9 Oil pressure sensor

10 Sensor for oil temperature

When in operation, the oil pump draws the oil from the oil tank through the thermostat to the oil radiator and forces it through the oil filter to the lubrication points. From here the engine oil is distributed to all lubrication points and flows from there back into the oil tank, driven by piston blow-by gases.

When installed, the thermostat bypasses the radiator when the oil temperature are below the normal operating temperature range.

In case of the oil filter mat clogging, an emergency pressure valve will open and unfiltered lube oil will flow to lubrication points.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

79-00-2

Fig. 79-00-3

79-00.3.1 Oil System Inspection


Line


79-00.3.1.3 Procedure



None

B. Oil System Inspection

Step

1

2

3

4

5

Inspect connections for leaks.

Check oil level. Replenish if required.

Action

Check conditions of oil lines, fire sleeves and connections for leakages. Check oil lines and fire sleeves for damage, overheating marks. Replace line or clamp if required.

Inspect oil tank vent line for damage and blockage. Replace if required.

Inspect oil radiator matrix for dirty/blocked.

Reference

6 Check the securing and conditions of Oil pressure sensor. Tighten sensor with torque



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

79-00-3

15Nm and secured with Loctite 243.

7 Check the securing and conditions of oil temperature sensors.

Check the securing and conditions of magnetic plug.

8 12-20-00 12

79-00.3.2 Oil Hoses and Lines Replacement

For maintenance instructions regarding oil hoses and lines replacement contact the aircraft manufacturer.



Approval Ref.:


AF 0480 0011 00

Date

05-Aug-12


Section

79-00-4

CTLS-LSA with ROTAX 912iS

Supplement S3 to the

Airplane Maintenance Manual (AMM)

CTLS-LSA with ROTAX 912iS

Airplane Type : CT

Airplane Model : CTLS-LSA

Airplane Registration Number : _______________

Airplane Serial Number : _______________

Document Number

Date of Issue

: AF 0480 0011_00

: 05-Aug-12

I RECORD OF SUPPLEMENT REVISIONS

II LIST OF EFFECTIVE SECTIONS

Contents

CHAPTER 01 – INTRODUCTION

01-00.1 General

01-00.2 Approval

01-00.5 Recovery of Certification Data

01-00.6 General Safety Information

01-00.7 Source to Purchase Parts

01-00.8 List of Disposable Replacement Parts

01-00.9 Recommended Torque Values

CHAPTER 02 – ORGANIZATION AND HANDLING OF THE

SUPPLEMENT

Contents

02-00.1.3 Figures

02-00.1.5 Abbreviations

02-00.2.1 Record of Revisions

02-00.2.2 List of Effective Sections

CHAPTER 04 – AIRWORTHINESS LIMITATIONS

Contents

04-00.1 General

04-00.4 Life Limited Components

CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECK

Contents

05-00.1 General

SECTION 05-10 – TIME LIMITS

05-10.1 General

05-10.2 Scheduled Maintenance Time Limits

05-10.3 Component Time Limits

SECTION 05-20 – SCHEDULED MAINTENANCE CHECK

05-20.1 General

05-20.2 Scheduled Maintenance Checklist CTLS-LSA

SECTION 05-30 – UNSCHEDULED MAINTENANCE CHECK

CHAPTER 11 – PLACARDS AND MARKINGS

Contents

11-00.1 General

11-00.2 Placards and Markings

SECTION 12-10 – REPLENISHING

12-10.1 General

12-10.2.1 Refueling and Defueling

12-10.2.2 Fuel Contamination Test

12-10.2.3 Fuel Flow Rate Check

CHAPTER 28 – FUEL SYSTEM

Contents

28-00.1 General

28-00.2 Description

28-00.3.1 Fuel System Inspections

28-00.3.2 Fuel Pumps Block Removal and Installation

28-00.3.3 Fuel Hoses and Lines Replacement

CHAPTER 71 – ENGINE

Contents

71-00.1 General

71-00.2 Description

71-00.3.1 Engine Cowlings Removal

71-00.3.2 Engine Mount Inspection

71-00.3.3 Air Intake Inspection

71-00.3.4 Starter Replacement

71-00.3.5 Generator Replacement

71-00.3.6 Other Engine Maintenance

CHAPTER 73 – ENGINE FUEL AND CONTROL

CHAPTER 74 – IGNITION

CHAPTER 75 – COOLING

Contents

75-00.1 General

75-00.2 Description

75-00.3.1 Cooling Inspection

75-00.3.2 Cooling Hoses and Lines Replacement

CHAPTER 76 – ENGINE CONTROLS