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Flight Design CTSW LSA Aircraft Operating Instructions

CTSW2006

SERIAL NUMBER:

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

Aircraft Type: CT-LSA

FLIGHT DESIGN Aircraft Operating Instructions

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Original Issue Date: 28.02.2005 Revision Date: 05.04.2006

1 Table of Contents Flight Design CTSW LSA ................................................................................................1 SERIAL NUMBER: ..........................................................................................................1

1 Table of Contents .................................................................................................2 2 General Information..............................................................................................4 3 Airplane and Systems Descriptions ......................................................................9

3.1 Engine: Rotax® 912 ULS ..............................................................................9 3.2 Propeller ......................................................................................................11 3.3 Fuel and fuel capacity..................................................................................12 3.4 Oil ................................................................................................................12 3.5 Operating weights and loading (occupants, baggage, fuel, ballast) ............12 3.6 Structures and Systems Description............................................................13

4 Operating Limitations..........................................................................................18 4.1 Stalling speeds at maximum takeoff weight (VS1 and VS0) ........................18 4.2 Flap extended speed range (VS0 to VFE)...................................................18 4.3 Maximum maneuvering speed (VA) ............................................................18 4.4 Never exceed speed (VNE) .........................................................................18 4.5 Crosswind and wind limitations....................................................................18 4.6 Service Ceiling.............................................................................................19 4.7 Load factors.................................................................................................19

5 Weight and Balance Information.........................................................................21 5.1 Installed equipment list ................................................................................21 5.2 Center of gravity (CG) range and determination..........................................22

6 Performance: ......................................................................................................27 6.1 Takeoff and landing distances.....................................................................27 6.2 Best rate of climb.........................................................................................27 6.3 Best angle of climb ......................................................................................27 6.4 Cruise speed ...............................................................................................27 6.5 RPM ............................................................................................................27 6.6 Fuel consumption (gallons (liters) per hour) ................................................27

7 Emergency Procedures ......................................................................................28 8 Normal Procedures.............................................................................................30

8.1 Preflight .......................................................................................................30 8.2 Engine start: ................................................................................................32 8.3 Taxiing.........................................................................................................32 8.4 Normal Takeoff ............................................................................................33 8.5 Climb ...........................................................................................................33 8.6 Cruise ..........................................................................................................33 8.7 Descent .......................................................................................................33 8.8 Before Landing ............................................................................................33 8.9 Normal landing ............................................................................................33 8.10 After Landing ...............................................................................................33 8.11 Shut down ...................................................................................................34 8.12 Short field takeoff and landing procedures ..................................................34 8.13 Balked landing procedure............................................................................34



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8.14 Information on stalls, spins and other useful pilot information .....................34 9 Aircraft Ground Handling and Servicing..............................................................35

9.1 Servicing fuel, oil, and coolant .....................................................................35 9.2 Towing (moving) and tie-down instructions .................................................35

10 Required Placards and Markings ....................................................................36 10.1 Airspeed indicator range markings ..............................................................36 10.2 Operating limitations on instrument panel ...................................................36 10.3 Passenger Warning .....................................................................................36 10.4 “NO INTENTIONAL SPINS” ........................................................................36 10.5 Miscellaneous placards and markings.........................................................36

11 Supplementary Information: ............................................................................38 11.1 Familiarization flight procedures ..................................................................38 11.2 Pilot operating advisories ............................................................................38

12 Supplements ...................................................................................................38 12.1 Three blade Neuform propeller....................................................................38

13 Revisions ........................................................................................................39 Appendix 1. Equipment List ..................................................................................41

AIRPLANES & ACCESSORIES.............................................................................41 ENGINE MANAGEMENT (not with Dynon EFIS/EMS) ..........................................48 AVIONIC & INSTRUMENTS ..................................................................................49

Appendix 2.................................................................................................................51 Variants of instrument panels for standard instrument board.....................................51 Appendix 3.................................................................................................................56 Variants of instrument panels for “Enlarged instrument panels” (Z-10113)................56 Appendix 4.................................................................................................................61 Instruction for the flap manual operation...................................................................61



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Note: In accordance FAR 21.190 Flight Design has established Aircraft Operating Instructions for the CTSW. The content and format is defined by ASTM standard F2245 and supplemented as deemed necessary by the manufacturer.

2 General Information Read this before your first flight! Each pilot must be familiar with the contents of the Aircraft Operating Instructions Manual and abide by all placards, limitations and checklists. Additionally, all Service Directives must be complied with and the Maintenance and Inspections Procedures manual must be used for all maintenance. For maintenance of the Rotax ® engine, the BRS emergency parachute system, and other installed equipment, refer to the original manufacturers’ manuals. Flight Design CT-LSAs are delivered worldwide, and comply with a variety of Light Sport airworthiness standards. All configurations are equipped with non-certified engines that meet ASTM standard F 2339. Unless otherwise specified, the information given is common to all configurations. Where different, the information is given in the appropriate appendices and supplements. The Flight Design CTSWs delivered in the U.S.A. are built to conform to the U.S. Light Sport Pilot rules and are intended for Day/VFR use. This manual is for guidance when operating a CTSW aircraft and is not intended to substitute for any required training received from an appropriately rated flight instructor. Manufacturer: Flight Design GmbH Sielminger Str. 65 D – 70771 L.-Echterdingen Basic description: The CTSW is a conventional, two seat, high-wing aircraft, with three-axis controls. The wings are fully cantilevered, incorporate integral fuel tanks, pushrod actuated ailerons and slotted type flaps that extend downwards for slow speed flight, and reflex upwards for cruise flight. The aircraft is equipped with an all-moving stabilator with a trim tab and tricycle landing gear with a steerable nose-wheel. The primary structures are made of carbon fiber reinforced plastic.



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Views, dimensions:



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Page Intentionally Left Blank



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3 Airplane and Systems Descriptions

3.1 Engine: Rotax® 912 ULS Description: The Rotax 912 ULS is a four cylinder, horizontally opposed, normally aspirated four stroke engine that incorporates air cooled cylinders with liquid cooled heads. The propeller is driven via a 2.43 to 1 reduction gear box. Limitations: Performance (sea level, ISA): 100 hp @ 5800 rpm (5 min) 95 hp @ 5500 rpm continuous Idle speed: 1400 rpm approx. Oil pressure: 29 to 73psi. (Normal range) 102psi.max. during a cold start

12psi is allowable below 3500 rpm Oil temperature: 266°F (130°C) max 120°F (50°C) min 190-230°F (90-110°C) normal operating range Cylinder head temperature: 284°F (135°C) max. Fuel pressure: 2.2 to 5.8 psi max. Engine starting and operating Temperature limits: -13°F (-25°C) Min. 120°F (50°C) Max. For a complete description of the engine and limitations, see the Rotax 912 Operator’s Manual.



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3.2 Propeller The standard propeller is a Neuform TXR2-65-47-101.6, which is a 2-blade, composite, ground adjustable propeller. For the optional Neuform three blade carbon fiber propeller, CR3-65-47-101.6 see the AOI supplements.



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3.3 Fuel and fuel capacity Fuel specification: Premium Automotive Unleaded per ASTM D 4814, minimum AKI 91 for Rotax 912ULS. Each wing has an integral fuel tank with a capacity of 17.1 gallons (65L) of which 16.5 gallons (62L) are usable. The total fuel capacity is 34.2 gallons (130L), of which 33.0 gallons (124L) are usable. For complete fuel specifications see the Rotax 912 Operator’s Manual.

3.4 Oil Only Name-brand, semi-synthetic or full synthetic, 4-stroke motorcycle oil should be used. The engine is equipped with a friction clutch to guard against sudden propeller stoppage: for this reason, oils with friction modifiers or additives that favor clutch slippage should not be used. Diesel engine oils are unsuitable because of their lower temperature tolerances. For oil change intervals, see the Maintenance and Inspection Procedures Manual. Note: If the engine is primarily run on AVGAS, more frequent oil changes will be required because of possible lead build-up. Oil capacity: 3.2 quarts. (min. 2.1) or 3 liters (min. 2) Max. Oil consumption: 0.2 pt/hr or 0.1 l/hr Note: For complete oil specifications see the Rotax 912 Operator’s Manual.

3.5 Operating weights and loading (occupants, baggage, fuel, ballast) Maximum take off weight: 1320 lbs (600 kg) Typical empty weight: 685 lbs (311 kg) Typical useful load 635 lbs (289 kg) Maximum weight per seat: 260 lbs (118kg) Maximum baggage weight per side: 55 lbs (25 kg) Maximum fuel load (34.2 gal) 205.2 lbs (93.2 kg) Minimum single pilot weight 120 lbs (54 kg)



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3.6 Structures and Systems Description Fuselage: The fuselage of the CTSW is made of multiple layers of carbon fiber and aramid (Kevlar®) laminated over a dense foam core creating a sandwich structure. The cabin can resist loads from all sides. This provides superior pilot and passenger crash protection and low structural weight. Wings: The cantilevered wing of the CTSW plugs into 4 hard points at the top of the cabin for attachment to the fuselage. The overlapping spars resist lift loads. The main spar caps are solid carbon fiber wrapped with S glass fibers over a dense Rohacell core. The wing “skin” is a carbon fiber sandwich. The ribs are molded carbon fiber and bonded into place. Wingtips: The wingtips of the CTSW are highly developed drooped type. They reduce stall speed, improve stability and low speed control of the CTSW. Fuel system: Fuel is gravity fed to the engine from two integral wing tanks. The total capacity is 34.2 gallons (130L). The usable fuel quantity is 33.0 gallons (124L). The operation of the fuel valve does not allow the ignition key to be inserted unless the fuel valve is in the “On” position. Electric system: The Rotax 912 series of engines are equipped with a “Lighting Coil” type alternator and a rectifier-regulator that converts and regulates the output of the alternator to a nominal 13.5 V – 14.2V 250W (roughly 18A). The battery for the electric starting system is 12V sealed, AGM type. The dual ignition system is a CDI (capacitive discharge). Landing gear: The landing gear of the CTSW is of the tricycle type. The nose wheel is steerable through a direct link to the rudder pedals. The main gear legs are heavy duty machined aluminum rods. Brakes: Hydraulic disk type, actuated through a handbrake lever. Parking brake is set by simultaneous use of the brake lever and parking brake valve. Control surfaces: The movable surfaces of the CTSW are of aramid-foam-aramid, carbon-foam-aramid, carbon-foam-carbon sandwiches with carbon fiber spars and attachment points.



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Rudder: The rudder is of a conventional type and it is aerodynamically balanced and is operated through foot pedals and cables. Stabilator: The stabilator is an all-moving type stabilizer with a counter-weight and anti servo/trim tab. It is actuated through a flexible push pull cable connected to the dual control sticks. Ailerons: The Frise type ailerons are controlled with push pull tubes and rod bearings and droop automatically with selection of the flaps. Flaps: The flaps are of the slotted type, and a pre-selector switch is used to position the flaps from -6° (or -12°) to +40º. The position of the flaps is indicated on the control panel. The flaps are protected by limit switches at the end limits. Pitch Trim: Pitch trim is activated through a control wheel located adjacent to throttle quadrant, and acts upon trim tab on the stabilator. Aileron Trim: Aileron trim is activated trough a control wheel located on the console between the pilot seats. Rudder Trim System: Rudder trim is activated through a control wheel located on the cabin bulkhead above the console and between the pilot seats. BRS Parachute system: Rocket deployed emergency parachute system. The system is actuated through the red, “T” handle located on the cabin bulkhead between the pilot seats. The T handle is secured on the ground with a tagged safety pin. The pin is removed for flight operations. To deploy the parachute, the T handle is pulled out fully to the stop.



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*Standard Instrument Panel



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* - instrument panels can be choosen from the standard list (please see Appendix 2 [or Appendix 3 – for Z-10113 “Enlarged instrument panels”]) with accordance to the list of the instruments from the Customer Order

Control Quadrant

Flap position indicator Ignition switch and starter



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FLYdat display: Rotax 912 ULS

Display Description Unit Resolution 1 Engine speed RPM 1 2 Hours of operation hour 0.1 3 Exhaust gas temp. Forward ºF (ºC) 1 or 10 4 Exhaust gas temp. Aft ºF (ºC) 1 or 10 5 Cylinder head temperature ºF (ºC) 1 6 EGT Left / Right display* Arrow N/A 7 Oil temperature ºF (ºC) 1 8 Oil pressure PSI 0.1 *note: The arrowhead pointer ← symbolizes left cylinder series. The arrowhead pointer → symbolizes right cylinder series. The left to right switching occurs at 6 to 8 second intervals. For a detailed description of the system, see the FLYdat User’s guide. FLYdat Warning and Alarms for the 912 ULS Display Unit Warning Alarm Engine speed RPM 5800 6000 EGT ºF(ºC) 1616 (880) 1652 (900) CHT ºF(ºC) 302 (135) 320 (145) Oil temperature ºF(ºC) 284 (130) 302 (140) Oil pressure: Max. PSI 87 (6.0 bar) 116 (8.0 bar) Oil pressure: Min PSI 29 (2.0 bar) 14.5 (1.0 bar) When one or more Warning limit value is exceeded, it is indicated on the display by flashing numbers, and the warning (alert) lamp also flashes. When one or more Alarm limit value is exceeded, it is indicated on the display by flashing numbers, and the warning (alert) lamp illuminates continuously.



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4 Operating Limitations

4.1 Stalling speeds at maximum takeoff weight (VS1 and VS0) VSO: Stalling speed or the minimum steady flight speed in the landing configuration. VS1: Stalling speed or the minimum steady flight speed obtained in a specific configuration. VS Flaps -6° (-12°) 44 KCAS (49 KCAS) 81 kmCAS (90 kmCAS) VS1 Flaps 0° 42 KCAS 77 kmCAS VS0 Flaps 40° 39 KCAS 72 kmCAS

4.2 Flap extended speed range (VS0 to VFE) The White arc on the airspeed indicator is from VS0 to VFE Flaps 15° VFE: Maximum flap extended speed. VFE: Flaps 0° 100 KCAS 185 kmCAS

15° 80 KCAS 148 kmCAS 30° 62 KCAS 115 kmCAS

40° 62 KCAS 115 kmCAS

4.3 Maximum maneuvering speed (VA) VA: Design maneuvering speed. (Above this speed, full or abrupt deflection of the control surfaces may cause structural failure). VA: 98 KCAS at 1320 lbs 184 kmCAS

4.4 Never exceed speed (VNE) VNE: Never-exceed speed VBRS: Maximum emergency parachute system operating speed. VNE: 145 KCAS 269 kmCAS VBRS: 160 KCAS 296 kmCAS

4.5 Crosswind and wind limitations The maximum demonstrated crosswind is 16 Kts (30 km). CAUTION: Due to the light operating weights and low minimum flight speeds of Light Sport Aircraft, operations with surface winds in excess of 25 knots (46 km) should not be attempted.



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4.6 Service Ceiling The Service Ceiling is the maximum altitude at which a climb rate of 100 ft/min. can be achieved. For the CTSW it is 14,000 feet (4,250 m). Note: An aircraft must be properly equipped and the pilot appropriately certificated for operations above 10,000 feet (3,000 m).

4.7 Load factors The maximum limit load factor is: + 4 g/ -2 g Flaps up + 2 g/ -0 g Flaps down 4.8 Maneuvers Aerobatics, including intentional spins are prohibited. Other limitations: Flight in to known icing is prohibited



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5 Weight and Balance Information

5.1 Installed equipment list Please see the Appendix 1.



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5.2 Center of gravity (CG) range and determination 5.2.1 Method for determining the Basic Empty Weight: Place the aircraft level on three suitable scales. (If only one scale is available, use leveling blocks and make separate measurements at each gear location). The aircraft leveling reference is the top of the console (tunnel) that runs between the pilot seats. Note the following measurements: G1: The weight found at the nose wheel location G2: The combined weight found at the main wheel locations. a: 35.63’’ (905 mm) The distance from the leading edge of the wing to the nose wheel. b: 58.07’’ (1475 mm) The distance from the main gear location to the nose wheel location. The Basic empty weight is the total of weights found at G1 and G2 G1 + G2 = G Using the following formula, find the Empty Center of Gravity location of the aircraft. ((G2 x b): G) – a = X X The distance from the leading edge of the wing to the Cg location Using the weights found on the scales and the weight and balance sheet determine the Basic Empty Weight. Complete the Weight & Balance and Equipment List.



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Sample Weight & Balance and Equipment List:

The acceptable empty Cg range is 9.45 to 13.78 inches.



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The acceptable empty Cg range is 240 to 350 mm.



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5.2.2 Determining the Weight and Balance Using the following examples, find the loaded center of gravity location. Using the center of gravity envelope, plot the loaded center of gravity. Loaded Aircraft Cg Location:



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6 Performance: The performance figures are based on sea level and standard atmospheric conditions and a gross weight of 1320 lbs (600 kg) unless otherwise noted.

6.1 Takeoff and landing distances Take-off distance over a 50ft (15 m) obstacle: 762ft (235 m). Landing distance over a 50ft (15 m) obstacle 967ft (295 m).

6.2 Best rate of climb VY = 78kts (154 km\h).

6.3 Best angle of climb VX = 66 kts (122 km\h).

6.4 Cruise speed Cruise speed at 75% power: 112 kts (205 km\h).

6.5 RPM Minimum Idle: 1400 Static 4700 Normal climb 4800 Maximum 5800 (5 min) Max. continuous 5500 Normal cruise 4200 – 5200 Cruise @ 75% 5200

6.6 Fuel consumption (gallons (liters) per hour) Climb power: 5.12 (19L) Normal Cruise power: 3.44. – 5.82 (13 – 22L) Max cruise: 6.88 (26L)



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7 Emergency Procedures Engine failure: The first action in the event of an engine failure is to lower the nose and to establish best glide speed: 63 kts (115 km\h). If the failure occurs during takeoff, it is often best to attempt a landing straight ahead and under control rather than try to turn and return to the runway. The next action should be to identify a field for landing, taking in to consideration obstacles, field length, and wind direction. Maintain a minimum speed of 63 kts(115 km\h) / 15° flaps until final approach. Before touchdown, select flaps 40° If there is sufficient time and the failure can be identified, a restart may attempted. If the restart is successful it may be possible to proceed to a suitable landing area and perform a precautionary landing. Engine Failure: In the event of fire shut off the engine: Turn off the ignition Shut off the fuel valve Slip away from the fire if possible Land as soon as possible The Emergency Parachute system (BRS): The BRS system may be used at a variety of altitudes and airspeeds. Situations that might warrant it’s use may include;

• A loss of control in Instrument Meteorological Conditions • A structural failure • A collision in flight • An irrecoverable spin • Pilot incapacitation • Jammed flight controls • Engine failure over hostile terrain

If possible, before activating the BRS, shut off the engine and tighten the seatbelts. To activate the system, pull the T handle all the way to the stop. CAUTION: The operator of a CTSW must be thoroughly familiar with the contents of the BRS 1350 LSA Parachute Manual and abide by all instructions and limitations within. Overturn on land:

• Carefully unfasten the seat belts and lower yourself first, then your passenger. • Be careful of any spilled fuel – there may be a fire hazard! • Leave the airplane immediately.



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8 Normal Procedures

8.1 Preflight A. Cabin 1. Aircraft documents Check 2. Flight controls Free and correct 3. Spar Bolts Installed and secure 4. Ignition Off, key out 5. Electrical equipment Off 6. Radio master Off 7. Master Switch On 8. Flaps Down 9. Master switch Off 10. Fuel Valve On B. Left side 1. Main gear and tire Check 2. Baggage compartment Secure 3. Antenna Check 4. Aft fuselage condition Check 5. Tie down Remove 6. Vertical Stabilizer Check 7. Stabilator Check 8. Servo tab Check 9. Tie-down Remove 10. Rudder Check C. Right Side 1. Vertical Stabilizer Check 2. Aft fuselage condition Check 3. Baggage compartment Secure 4. Main gear and tire Check D. Left wing 1. Flap Check 2. Aileron Check 3. Wing tip Check 4. Wing leading edge Check 5. Pitot tube Check 6. Tie down Remove 7. Fuel cap Secure



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E. Nose 1. Cowling Secure 2. Exhaust stack Secure 3. Nose gear Check 4. Engine intakes Clear 5. Landing Light Check 6. Spinner Secure 7. Propeller Check 8. Cowling Secure 9. Oil quantity Check 10. Fuel Drain and Check 10. Static port Clear F. Right Wing 1. Leading edge Check 2. Fuel Cap Secure 3. Tie down Remove 4. Wing tip Check 5. Aileron Check 6. Flap Check



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8.2 Engine start: 1. Preflight Complete 2. Parking Break Set 3. Carburetor heat Off 4. Circuit breakers In 5. Radios and Electrical equipment Off 6. Master Switch On 7. Anti-collision lights On 8. Fuel Valve Open 9. Ignition key In 10. Choke As required 11. Throttle Closed 12. Ignition Switch Start and release 13. Choke Adjust 14. Oil pressure Check 15. Radios Set 16. Flaps Up

8.3 Taxiing 1. Breaks and Steering Check Before Takeoff 1. Parking Brake Set 2. Seat belts Secure 3. Doors Closed 4. Flight Controls Free and correct 5. Flight Instruments Set 6. Choke Off 7. Carburetor heat Off 8. Throttle 3200 rpm. 9. Engine Indications Check 10. Ignition Check Left, Right, & Both (max. drop 300 rpm./ max. diff. 120 rpm.) 11. Oil temperature Min 124°F (51°C) 11. Throttle Idle 12. Flaps Set 13. Trim Set 14. Radios Set 15. Parking Brake Release



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8.4 Normal Takeoff 1. Flaps 0° to 15° 2. Throttle Full 3. Carb heat Off 3. Climb 59 kts (110 km\h) Flaps 15° 86 kts (160 km\h) Flaps -6°

8.5 Climb 1. Flaps Flaps -6° 2. Airspeed 86 kts (160 km\h) 3. Power 5500 rpm (max. continuous) Note: Best angle of climb speed: Vx = 66 kts, Flaps 0 Best rate of climb speed Vy = 78 kts, Flaps 0

8.6 Cruise 1. Power Set 2. Engine Instruments Check

8.7 Descent 1. Carburetor heat As required 2. Altimeter Set

8.8 Before Landing 1. Seatbelts Secure 2. Airspeed 54 kts (100 km\h) 3. Flaps 15° to 40°

8.9 Normal landing Flaps Airspeed

8.10 After Landing 1. Landing light Off 2. Flaps Retract



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8.11 Shut down 1. Parking brake Set 2. Radios Off 3. Electrical equipment Off 4. Ignition Off 5. Master switch Off

8.12 Short field takeoff and landing procedures Flaps 15° Parking brake Set Power Full Brakes Release Rotate 44 kts (80 km\h)

8.13 Balked landing procedure Power Full Flaps 15° Airspeed 59 kts (110 km\h)

8.14 Information on stalls, spins and other useful pilot information Stalls: The CTSW exhibits conventional characteristics with a slight buffet at the onset of the stall. There is no tendency to roll in a coordinated stall. Directional control should be maintained through use of the rudder. Recovery is also conventional: release pressure on the control stick to reduce the angle of attack. Apply full power, and slowly recover. Spins The CTSW is not certified for spins In the event of an unintentional spin: 1. Reduce power to idle 2. Center the ailerons 3. Apply rudder in the opposite direction of rotation 4. When the rotation stops, smoothly recover from the resultant dive. If an unintentional spin is entered and the altitude is such that a safe recovery cannot be made, the ballistic parachute system should be deployed. Steep turns Enter with coordinated use of rudder and ailerons. Increase pitch and power as necessary to maintain altitude and airspeed. Do not exceed 60° of bank angle. Lead the roll out the number of degrees equal to half the bank angle.



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9 Aircraft Ground Handling and Servicing

9.1 Servicing fuel, oil, and coolant Fuel The fuel tanks are equipped with vented fuel caps that are located on the upper surface of the wing. The fuel caps must be in place for flight, with the vents facing forward. A calibrated dip stick, with left tank and right tank indications, is supplied to check the fuel quantity. The aircraft must be grounded during refueling. Should fuel be spilled on the Note: The aircraft finish may be damaged by exposure to fuel; any spills should be immediately cleaned up. Oil For an accurate oil measurement: 1. Set the Parking brake 2. Check the Master switch is off, and the Ignition key is out. 3. Remove the top cowling. 4. Open the Oil tank 5. Turn the propeller 3 to 4 times in the direction of rotation. 6. Check the oil level Coolant To check the coolant level: 1. Set the Parking brake 2. Check the Master switch is off, and the Ignition key is out. 3. Remove the top cowling. 4. Open the cap of the coolant tank and add coolant to fill up the tank. 5. Make sure that no air is inside the cooling system. 6. Close the coolant tank cap. 7. If necessary, add coolant to the expansion tank.

9.2 Towing (moving) and tie-down instructions Moving the CTSW: The aircraft can be moved by one person. 1. Check that the parking brake is off. 2. Check that the area around the aircraft is clear of obstacles and people. 3. Push down on the tail boom of the aircraft to lift the nose gear off the ground. 4. Push the aircraft in needed direction. Tie down instructions: 1. Install mooring lines from the ground to the tie-down rings on the undersurface of the wings. 2. Place the tail boom tie-down strap around the tail boom and secure to the ground with mooring lines.



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10 Required Placards and Markings

10.1 Airspeed indicator range markings White range (flap operating range) 39 ... 62 kts (72 … 115 km/h) Green range (normal operating range) 44 ... 120 kts (81 … 222 km/h) Yellow range (caution range) 120 ...145kts (222 … 269 km/h) Red line (never exceed speed) 145 kts (269 km/h)

10.2 Operating limitations on instrument panel MAX: RPM 5800, EGT 1616F, CHT 248F, Oil Temp. 266F, Oil Press. 102 psi

or MAX: RPM 5800, EGT 880ºС, CHT 120ºС, Oil Temp. 130ºС, Oil Press. 7 bar

10.3 Passenger Warning The warning “This aircraft was manufactured in accordance with Light Sport Aircraft airworthiness standards and does not conform to standard category airworthiness requirements” is placed on the instrument panel or in a place where a passenger will see it.

10.4 “NO INTENTIONAL SPINS” The placard “NO INTENTIONAL SPINS” is placed close to the airspeed indicator.

10.5 Miscellaneous placards and markings. Type of Fuel: 2 x beside filling cap

Tachometer 5800 RPM Oil pressure gauge max 102 psi 7 bar

min 12 psi 0,8 bar

Oil temperature gauge 266ºF 130ºС for ULS, Water temperature gauge 248ºF 120ºС for ULS, cylinder head



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Throttle lever box

Choke lever box

Stabilator Trim lever box

Brakes lever box

Flaps -6° (-12°), 0°, 15°, 30°, 40° flap indicator

Oil quality oil tank Circuit Breakers left side of the central console Main Circuit Breakers right side of the central console Maintenance/packing interval BRS Manual & Chute placard

Baggage Compartment Baggage area



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11 Supplementary Information:

11.1 Familiarization flight procedures See the Pilot Training Supplement for familiarization procedures

11.2 Pilot operating advisories None at this time

12 Supplements

12.1 Three blade Neuform propeller



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13 Revisions The Revisions pages are updated by Flight Design each time revision is issued. They contain a list of all revisions made to the Pilot Operation Handbook since its original issue.

Revision No. Date Released Affected Chapters

Affected Pages

Approved By

Original Issue 28.02.2005 N/A N/A

2 General Information

6; 8

3 Airplane and Systems Descriptions

13; 14

4 Operating Limitations

15; 17; 19 1 20.07.2005

10 Required Placards and Markings

36

4.5Crosswind and wind limitations

15

6 Performance 27

8.2 Engine starting 31

8.4 Normal takeoff 32

8.5 Best angle of climb speed (VX);8.6 Cruise

33

2 05.10.2005

10.5Miscellaneous placards and markings

36

3 05.04.2006 Total revised; Name of document changed; insert part 12, Appendix 1, Appendix 2, Appendix 3, Appendix 4

1-62



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Appendix 1. Equipment List Please check local certification rules !

AIRPLANE READY TO FLY CONSIST OUT OF A COMPONENT

"A"

CT 2006

MTOW 600kg (safe load 4 g) Vne 301 km/h Certification UK 450 kg - Germany 472,5 kg - Australia 544 kg -

Canada 560 kg - USA 600 kg

Description AIRPLANES & ACCESSORIES

A-10001 Airplane BfU/LTF-UL CTSW 2006 ready to fly no rescue Equipment

Shortwings with downwards orientated winglets (reduces induced drag and increases directional stability)

Increased rudder fin area Increased stabilator antitap 3 tones painting inside the cabin 2-components outside painting - white 2 layers Swiss or German aeronautical windows with green tone Adjustable seats (length and hight) 4-points safety belts for each seat 2 luggage compartments accessible from outside & inside Fabric cover for the luggage compartments Luggage securety hooks in the luggage compartment 2 lockers on the cabin floor Standard cockpit with three single panels Handcap on cowling for quick oil and water check Extra wide cabin doors with gas spring Double steering, three axes Prepared for rescue system Nylon Belts Plexiglass steering cover Manual stabilizer trim by lever Electrical flap for -12° to +40° with pre-selection switch Switch board panel with automatic fuses Combination key switch Central fuel valve 2 wing tanks for 65l = 130 l fuel Steerable spring damped front wheel Hydraulic disk brakes Flight Instruments Speed indicator D 80mm Single pointer altimeter D 80 mm Magnetic compass Slip & bank indicator



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Engine: Rotax 912 UL2 (80 HP) ready to fly installed Airbox & Carburator heating RPM meter Oil pressure "bar" only Oil temperature "°C" only Cylinder head water temperature measurer "°C" only Huge Batterie Rotax engine guarantee Propeller Neuform ground adjustable

Ground adjustable Neuform propeller 2 blades, with Spinner and Spinner plate, already mounted

Flight and service manual, Engine and Airplane Logbook



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A-10050 Airplane BfU/LTF-UL CTSW ready to fly no rescue Equipment

Shortwings with downwards orientated winglets (reduces induced drag and increases directional stability)

3 tones painting inside the cabin 2-components outside painting - white 2 layers Swiss or German aeronautical windows with green tone Adjustable seats (length and hight) 4-points safety belts for each seat 2 luggage compartments accessible from outside & inside Fabric cover for the luggage compartments Luggage securety hooks in the luggage compartment 2 lockers on the cabin floor Standard cockpit with three single panels Handcap on cowling for quick oil and water check Extra wide cabin doors with gas spring Double steering, three axes Prepared for rescue system Nylon Belts Plexiglass steering cover Manual stabilizer trim by lever Electrical flap for -12° to +40° with pre-selection switch Switch board panel with automatic fuses Combination key switch Central fuel valve 2 wing tanks for 65l = 130 l fuel Steerable spring damped front wheel Hydraulic disk brakes Flight Instruments Speed indicator D 80mm Single pointer altimeter D 80 mm Magnetic compass Slip & bank indicator



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Engine: Rotax 912 UL2 (80 HP) ready to fly installed Airbox & Carburator heating RPM meter Oil pressure Oil temperature Cylinder head water temperature measurer Huge Batterie Rotax engine guarantee Propeller Neuform ground adjustable

Ground adjustable Neuform propeller, with Spinner and Spinner plate, already mounted

Flight and service manual, Engine and Airplane Logbook



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A-10011 Airplane CTSW 2006 LSA SPORT Version ready to fly no rescue Equipment difference to CTSW 2006 BFU/LTF-UL Outer paint and finish improved Add-on parts reinforced (farings, wheel spads) More stabile seats Touch stability improved, by thicker or different layers A-10060 Airplane CTSW LSA SPORT Version ready to fly no rescue Equipment difference to CTSW BFU/LTF-UL Outer paint and finish improved Re-inforced optional parts (fairings, wheel pants) More comfortable seats with thicker padding. Touch stability improved, by thicker or different layers A-10102 Airplane component CTSW 2006 Section S ready to fly no rescue Equipment difference to CTSW 2006 BFU/LTF-UL 2-components outside painting - white 1 layers White door windows 0,5 mm thinner No Fabric cover for the luggage compartments No plexiglass steering cover Not prepared for rescue system 3 Fuses Weight optimised and selected Parts Flight Instruments Bräuniger ALPHAMFD Combi instrument Magnetic compass Slip & bank indicator Engine: Rotax 912 ULS (100 HP) already installed No Airbox & no carburator heating Bräuniger ALFAMFD Combi instrument Small Batterie Rotax engine guarantee Propeller Neuform ground adjustable

Ground adjustable Neuform propeller, with Spinner and Spinner plate, already mounted

Little comfort package Heating system with stanless steel muffler Wheel- and main leg gear fairings

Additional MECAPLEX double fresh air windows in the left door window

Additional map holders in the cockpit Two sockets 12V Door locks Parking brake Flight and service manual, Engine and Airplane Logbook



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B-00010X Addition on price 912 ULS 100HP (n. Sec. S) big starter Rotax 912 ULS with big Starter instead 912 UL2 B-00012X Addition on price 912 FR ULS 100PS (n. Sec. S) France

Rotax 912 ULS with big Starter instead 912 UL2, special version France with blue cylinder heads

B-00011X Oil- and Waterthermostat (Only 912ULS) with big cooler Optimizes the Oil- and Watertemperatur

C-00205x Add-On Neuform 3 Blade Prop. Black & White w- L./E protection

C-00200x Add-On price Kaspar 3-Blade var.p. prop In-flight adjustable 3-Blade propeller, mechanical-hydraulic C-00201x Add-On price Neuform 3-Blade var.p. prop In-flight adjustable 3-Blade propeller, mechanical-hydraulic Z-11020X Rotax slipper clutch

Protection against shock loading of engine by ground contact of

propeller D-12100X Junkers Light Speed Rescue system w. add. Belts Max. 300 km/h, mounted, belts inside structure D-12200X BRS 5 1050 rescue system soft pack w. add. Belts 275 km/h, mounted, belts inside structure D-12300X BRS 1350 Rescue system 600 kg - 1350 lbs, mounted, belts inside structure D-12400X BRS Kevlar front harness instead of standard harness Special BRS Kevlar belts instead of standard belts

Z-10100++ Comfort package (not Section S) 2006 w. 3-aches trim system and new depositions

Z-10010x 3-Axes trim system manual Z-10110x Heating system with stanless steel muffler Z-10120x Wheel- and landing gear fairings Z-10150x 12 V connector Z-10160x Additional MECAPLEX double fresh air windows in door windows Z-10170x Additional map holders in the cockpit, mainframe and doors Z-10130x Door locks Z-10140x Parking brake Z-10180x ACL- & Position lights (green, white, red) LED version Z-10114++ Sun Visors left & right



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Z-10111X Special heating for very low out side temperaturs Z-10112 Sport seats with adjustable headrest and improved upholstery

Z-10113 Enlarged instrument panels add-on price (not with standard VDO engine instruments)

Z-10172 Cowling with Quick Fasteners Z-10161x Photowindow Add-On price instead of ventilation window Z-10201 Cross country Heavy Duty Landing Gear Z-10200x Tundra Wheels w. wheel fairings (only together with Z-10201) Frontwheel 6x4 Mainwheels 6x6 Z-10202X Stronger tires 6 ply Z-10210x Floats prep. (with metal attchm. parts "ORDER MAY 2005"

Stainless steel bolts & nuts, special surface treatment, metal parts for float attachment

Z-10220x 3 Wheel Amphibfloats ("1150") " Add-On price instead of trycicle landing gear

Floats complete mounted

Z-10230x 4 Wheel Amphibfloats ("1300") "ORDER from 05/2006" Add-On price instead of trycicle landing gear

Floats complete mounted Z-10250 Landing light none certified Z-10251 Instrument lights LED lights per instrument Z-10252 Cabin light & fuel indicator light LED lights trimable Z-13050.1++ Black leather seats (add-on-price) Seats and stick base covered with same leather Z-13050.2++ Light Brown leather seats (add-on-price) Seats and stick base covered with same leather



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Z-13060.1++ Three color decals SN 1 Z-13060.2++ Three color decals SN 2 Z-13060.3++ Three color decals SN 3 Z-13060.4++ Three color decals SN 4 Z-13061.1++ Three color decals SW 1 Z-13061.2++ Three color decals SW 2 Z-13061.3++ Three color decals SW 3 Z-13061.4++ Three color decals SW 4 Z-13062.1++ Three color decals UP 1 Z-13062.2++ Three color decals UP 2 Z-13062.3++ Three color decals UP 3 Z-13062.4++ Three color decals UP 4 Z-14000X Add-On Aero towing equipped Reinforcement of fuselage & fin, clutch, mirrow, special cooler Z-14100X Add-On Reinf. of fusel. for tow.(no fin & clutch) Z-14200X Add-On fin for towing (no clutch) only with Z-14100X Z-13070 Call Signs Making and mounting of call signs Confirmity Statement at costs

Export Certificate

ENGINE MANAGEMENT (not with Dynon EFIS/EMS)

Z-15100X Add-on price Rotax Fly Dat °C & bar

Digital engine information system instead of analog instruments: black box, 4* EGT, 1*CHT, oil temp., RPM, hours, oil pressure. Warning when maximum values are exeeded!

Z-15101X Add-on price Rotax Fly Dat °F & PSI

Digital engine information system instead of analog instruments: black box, 4* EGT, 1*CHT, oil temp., RPM, hours, oil pressure. Warning when maximum values are exeeded!

Z-15100.1X Add-on price for UMA analogue gauges in °C & bar Z-15101.1X Add-on price for UMA analogue gauges °F & PSI



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AVIONIC & INSTRUMENTS Z-10800x DYNON 100 - 120 EFIS & EMS Dual Display (only with Z-10113)

Complete electronic flight and engine management. ASI und Altimeter as 2 1/4" analog back up.

Z-10350x King KY 97 A Com & Transponder KT 76 A Mode A/C (*

PM intercom, 2 PTT push bottoms, 2 Antennas, 2 Dave Clark H13.10 S head sets, ready mounted. FTZ & FAA certified.

Transponder incl. antenna and altitude encoder Z-10500x Becker AR 4201 COM & Transponder ATC 4401-175

PM intercom, 2 PTT push bottoms, 2 Antennas, 2 Dave Clark H13.10 S head sets, ready mounted. FAA & FTZ certified.

Transponder incl. antenna and altitude encoder Z-10550x Becker AR 4201 COM & Transponder BXP6401-2-(01) Mode S

PM intercom, 2 PTT push bottoms, 2 Antennas, 2 Dave Clark H13.10 S head sets, ready mounted. FAA & FTZ certified.

Transponder incl. antenna and altitude encoder Z-10900x GARMIN SL 40 COM & Transponder GTX 327 Mode C

PM intercom, 2 PTT push bottoms, 2 Antennas, 2 Dave Clark H13.10 S head sets, ready mounted. FAA certified.

Transponder incl. antenna and altitude encoder Z-10201X NO HEADSETS Z-10650x Skyforce IIIC enhanced Atlantic Intl (* (only with Com/T package)

Incl. antenna and data cable cockpit mounted and 57 mm Instruments in the standard panel

Z-10651x Skyforce IIIC enhanced USA (* (only with Com/T package)


Z-10652x Skyforce IIIC enhanced Pacific Intl (* (only with Com/T package)


Z-10950x Garmin GPS 396 American Database (only with Com/T package) Incl. antenna and data cable cockpit mounted



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Z-10960x Garmin GPS 296 European Database (only with Com/T package) Incl. antenna and data cable cockpit mounted Z-10961x Garmin GPS 296 American Database (only with Com/T package) Incl. antenna and data cable cockpit mounted Z-10700x ELT (*

Emergency transmitter (required in Austria), completely mounted -

FAA certified

Z-10025x Pictoral Pilot 1-Axes Autopilot not certifed Aileron & turn & bank indicator Z-10022x Altrak Altitude hold (none certified only with Z-10025x) Stabiliser Z-10040x TruTrack DigiFlight IIVS 2-Axes Autopilot not certifed Aileron & Stabiliser with vertical steering Z-15451.2X Variometer ft/min Z-15452X Add-on price 3-P Altimeter only for 80 mm panel layout Z-16000.1X ASI in km/h Z-16000.3X ASI in kts Z-16100.1X Altimeter in mbar Z-16100.2X Altimeter in hg



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Appendix 2.

Variants of instrument panels for standard instrument board



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Appendix 3.

Variants of instrument panels for “Enlarged instrument panels” (Z-10113)



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Appendix 4.

Instruction for the flap manual operation 1 Для активации ручного режима платы управления закрылками необходимо:

1) To activate the manual operation of the flap control printed circuit board ( PCB) , do as follows:

А) Ручку управления закрылками повернуть на 180° относительно положения 15°, после чего засвечиваются светодиод VD1 и центральные сегменты индикатора автоматического режима (при условии работоспособности процессора). Это означает включение ручного режима и отключение автоматического . Система управления находится в режиме ожидания.

A) Turn the flap control switch by 1800 with reference to 150 position to illiminate the LED display VD 1 and central segments of the automatic operation indicator (provided the processor is in proper working condition)

This is to notify that the manual operation is switched on and the automatic operation is switched off. The control system is in the stand-by mode.

VD1

В). При повороте ручки управления на 1800

относительно положения 300 начинается движение закрылков вверх.

B) When the flap control switch is turned by 1800 with reference to 300 position, the flaps start to retract( flaps move up)

VD2

Ограничителем хода закрылков является концевой выключатель, расположенный на пластине электро-механизма МТ-10, что соответствует максимальному отклонению закрылков вверх. Во время движения закрылков светится светодиод VD2.

Located on the plate of the electric mechanism MT-10 is the limit switch which has the function to limit the movement of flaps. This corresponds to the maximum up deflection. When the flaps move, the LED display VD2 illuminates.

C) После остановки движения закрылков ручку переключателя необходимо вернуть в нейтральное положение – (пункт 1А)

C) When the movement of flaps has been accomplished, the control switch should be reset to a neutral position (see item 1A).



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D) При повороте ручки управления на 1800 относительно положения 00 начинается движение закрылков вниз. При этом загорается светодиод VD3. Ограничителем хода является концевой выключатель на МТ-10

D) When the flap control switch is turned by 1800 with reference to 00 position, the flaps start to extend ( flaps move down). At this point, the LED display VD3 illuminates. The limit switch located on the MT-10 has the function to limit the movement of flaps.

VD3 Е) Промежуточные положения закрылков (например 00,150, 300) выбираются визуально по положению закрылков относительно крыла. При необходимости перевести закрылки в промежуточные положения, необходимо задать движение закрылков вверх или вниз до требуемого положения, после чего остановить ход закрылков переводом ручки управления в нейтральное положение (пункт 1А)

E) Intermidiate flap position ( for instance, 00,150,300) are to be selected by sight according to the position of flaps with respect to the wing. To set the flaps in intermediate positions, if necessary,encure that flaps move up or down as far as the required position.After that,stop the movement of flaps by setting the flap control switch in a neutral position (item 1A).

2) Для перехода в автоматический режим переместить ручку в одно из положений (-12°, 0°, 15°, 30°, 40°) при этом появится индикация на дисплее, соответствующая выбранному положению. Остановка движения закрылков в этих положениях происходит автоматически. При необходимости перепрограммировать установленные положения автоматического режима действовать по инструкции «Установки положений закрылков».

2) To activate the automatic operation,set the switch in one of the designated positions (-12°,0°, 15°, 30°, 40°), accompanied by an indication at the display corresponding to the selected position.The movement of flaps in these positions is to be stoped automatically. To change the settings of the automatic operation,if necessary,comply with the instructions «Setting-up of flap positions».

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