Ctswmanual

Flight Design
AIRCRAFT OPERATING INSTRUCTIONS

CTSW
(CTSW / CTSW-2006 / CTSW Classic / CTSW Advanced)
SERIAL NUMBER:
THIS DOCUMENT AND THE TECHNICAL DATA HEREON DISCLOSED ARE PROPRIETARY TO FLIGHT DESIGN AND SHALL
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FLIGHT DESIGN
Aircraft Operating Instructions Aircraft Type: CTSW
FLIGHT DESIGN Page: ii
Record of Revisions
Revision Number Revision Date Approved

Original Issue 28-Feb-2005
1 20-Jul-2005
2 05-Oct-2005
3 05-Apr-2006
4 05-Dec-2006
5 30-Dec-2006
5a 16-Apr-2007
5b 13-Jul-2007
6 01-Apr-2008
7 29-Apr-2008
List of Effective Pages
Chapter Page Revision Chapter Page Revision

Chapter 1 iii 7 Chapter 9 9-1 7
iv 7 9-2 7
Chapter 2 2-1 7 9-3 7
2-2 7 Chapter 10 10-1 7
2-3 7 10-2 7
2-4 7 10-3 7
Chapter 3 3-1 7 10-4 7
3-2 7 Chapter 11 11-1 7
3-3 7 11-2 7
3-4 7 Chapter 12 12-1 7
3-5 7 Appendix 1 1 7
3-7 7 Appendix 2 2 7
3-7 7 3 7
3-8 7 4 7
3-9 7 5 7
Chapter 4 4-1 7 6 7
4-2 7 7 7
4-3 7 8 7
4-4 7 9 7
Chapter 5 5-1 7 Appendix 3 10 7
5-2 7 11 7
Chapter 6 6-1 7 12 7
6-2 7
Chapter 7 7-1 7
7-2 7
7-3 7
7-4 7
Chapter 8 8-1 7
8-2 7
8-3 7
8-4 7
8-5 7
8-6 7
8-7 7
Original Issue Date: 28-Feb-2005

AU 010 01000 Rev. No: 7 Revision Date: 29-Apr-2008
FLIGHT DESIGN Page: iii
1 Table of Contents
1 Table of Contents .................................................................................................iii

2 General Information ...........................................................................................2-1
3 Airplane and Systems Descriptions ...................................................................3-1
3.1 Engine: Rotax® 912 Series ........................................................................3-1
3.2 Propeller .....................................................................................................3-2
3.3 Fuel and fuel capacity.................................................................................3-2
3.4 Oil ...............................................................................................................3-3
3.5 Operating weights and loading (occupants, baggage, fuel, ballast) ...........3-4
3.6 Structures and Systems Description...........................................................3-5
3.7 Carbon monoxide detector .........................................................................3-9
4 Operating Limitations.........................................................................................4-1
4.1 Stalling speeds at maximum takeoff weight (VS1 and VS0).......................4-1
4.2 Flap extended speed range (VS0 to VFE)..................................................4-1
4.3 Maximum maneuvering speed (VA) ...........................................................4-1
4.4 Never exceed speed (VNE) ........................................................................4-2
4.5 Crosswind and wind limitations...................................................................4-2
4.6 Service Ceiling............................................................................................4-2
4.7 Load factors................................................................................................4-2
4.8 Maneuvers..................................................................................................4-3
4.9 Other limitations..........................................................................................4-3
5 Weight and Balance Information........................................................................5-1
5.1 Installed equipment list ...............................................................................5-1
5.2 Center of gravity (CG) range and determination.........................................5-1
6 Performance ......................................................................................................6-1
6.1 Takeoff distance .........................................................................................6-1
6.2 Best rate of climb........................................................................................6-1
6.3 Best angle of climb .....................................................................................6-1
6.4 Cruise speed ..............................................................................................6-1
6.5 RPM ...........................................................................................................6-1
6.6 Fuel consumption .......................................................................................6-1
7 Emergency Procedures .....................................................................................7-1
8 Normal Procedures............................................................................................8-1
8.1 Preflight ......................................................................................................8-1
8.2 Engine start ................................................................................................8-3
8.3 Taxiing........................................................................................................8-3
8.4 Normal takeoff ............................................................................................8-4
8.5 Climb ..........................................................................................................8-4
8.6 Cruise .........................................................................................................8-4
8.7 Descent ......................................................................................................8-4
8.8 Before landing ............................................................................................8-4
8.9 Normal landing ...........................................................................................8-4
8.10 After landing ...............................................................................................8-5
8.11 Shut down ..................................................................................................8-5
8.12 Short field takeoff procedure ......................................................................8-5

FLIGHT DESIGN Page: iv
8.13 Balked landing procedure...........................................................................8-5

8.14 Information on stalls, spins and other useful pilot information ....................8-5
9 Aircraft Ground Handling and Servicing.............................................................9-1
9.1 Servicing fuel, oil and coolant .....................................................................9-1
9.2 Ground handling and tie-down instructions ................................................9-1
10 Required Placards and Markings .................................................................10-1
10.1 Airspeed indicator range markings ...........................................................10-1
10.2 Operating limitations on instrument panel ................................................10-1
10.3 Passenger Warning ..................................................................................10-1
10.4 “NO INTENTIONAL SPINS” .....................................................................10-2
10.5 Miscellaneous placards and markings......................................................10-2
11 Supplementary Information ..........................................................................11-1
11.1 Familiarization flight procedures ...............................................................11-1
11.2 Pilot operating advisories .........................................................................11-1
12 List of amendments......................................................................................12-1
Appendix 1. Current equipment List............................................................................. 1
Appendix 2. Variants of instrument panels................................................................... 2
Appendix 3. Samples of the Weight & Balance and Equipment List .......................... 10

FLIGHT DESIGN Page: 2-1
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 CTSWs 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 F2339. 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.

Views and dimensions, inches (mm)

Geometrical parameters
Geometry, mm / inch
Max. length 6214 244.6
Max. height 2165 85.3
Areas, m2 / ft2
Wing 9.98 107.4
Stabilator 1.65 17.75
Vertical tail 1.32 14.20
Wing span, m / inch 8.53 335.8
Aspect ratios
Wing 7,29
Stabilator 3,40

Page Intentionally Left Blank

3 Airplane and Systems Descriptions
3.1 Engine: Rotax® 912 Series
Description
The standard engine is a Rotax 912 UL2, a four cylinder, horizontally opposed, normally
aspirated four stroke engine that incorporates air cooled cylinders with liquid cooled heads.
Limitations
ROTAX 912 UL2 ROTAX 912 ULS

Take-off performance: 59.6 KW / 81 HP 73.5 KW / 100 HP
(at 5.800 RPM, max 5 min)
Max. continuous performance 58 KW / 79 HP 69 KW / 95 HP
(at 5.500 RPM)
Min RPM before take-off, RPM 4.400 4.500
Max RPM before take-off, RPM 5.500
Max cylinder head temperature 120 ºC
248 F
For a complete description of the engine and limitations see the Rotax 912 Operator’s Manual

3.2 Propeller
For a complete description of the propeller see Operator’s Manual for appropriate propeller
Applicability
CTSW CTSW CTSW

Classic Light Classic Advanced
Neuform TXR-65, 2-blade •
Neuform CR3-65, 3-blade • •
Kaspar, 3-blade in-flight adjustable •* •*
* - available as an option
3.3 Fuel and fuel capacity
The fuel valve is purely on/off and has to be in the appropriate maximum position. This
engine does not have a mixture valve or require leaning.
Fuel specification: Premium Automotive Unleaded per ASTM D 4814, minimum AKI 91
for Rotax 912ULS.
SUPER leaded, DIN 51600, ONORM C 1103
EURO-SUPER ROZ 95 unleaded, DIN 51603, ONORM 1101
SUPER PLUS ROZ 98 unleaded, DIN 51607, ONORM 1100
AVGAS 100 LL.
ATTENTION! AVGAS loads the valve seats with high lead content and forms more
combustion chamber deposits and should be used only in case of
vapor lock or insufficient octane on auto fuel.
Each wing has an integral fuel tank with a capacity of 65l / 17 U.S. gallons of which 62l /
16.5 gallons are usable.
The total fuel capacity is 130l / 34 U.S. gallons of which 124l / 33 gallons are usable.
For complete fuel specifications see the Rotax 912 Operator’s Manual

3.4 Oil
Only brand-name semi-synthetic or full synthetic 4-stroke motorcycle oil should be used.
ROTAX 912 UL2 ROTAX 912 ULS

Oil, normal operating pressure (below 3.500 RPM) 2.0 – 5.0 bar
29 – 73 psi
Oil, min operating pressure (above 3.500 RPM) 0.8 bar
12 psi
on very cold start momentarily 7 bar allowed
Min/max temperature measured at the oil inlet of 50 / 130 ºC
the engine 120 / 266 ºF
Optimum operating temperature 90-110 ºC
190-230 ºF
Oil capacity 3.0 l, min 2.0 l
6.4 liq pt, min 4.2 liq pt
Max oil consumption, L per hour / liq pt per hour 0.06 / 0.13
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.
For complete oil specifications see the Rotax 912 Operator’s Manual

3.5 Operating weights and loading (occupants, baggage, fuel, ballast)
Operating weights
LSA
registration
USA Australia
kg lbs kg lbs
Max. take-off weight 600 1323 544 / 600 1199 / 1323
Empty plane 314* 693* 303 668
Typical payload 297 654 241 / 297 531 / 654
* - with BRS 1350 HS
BFU / LTF-UL
registration
kg lbs
Max. take-off weight 472.5 1042
Empty plane 268 590
Typical payload 180 / 114.5* 396 / 252*
* - with full tanks
BCAR Section S
registration
kg lbs
Max. take-off weight 450 922
Empty plane 265 584
Typical payload 185 407
Loading
LSA BFU / LTF-UL BCAR(S)

registration registration registration
Maximum weight per seat 118 kg 100 kg 100 kg
260 lbs 220 lbs 220 lbs
Maximum baggage weight per side 25 kg
55 lbs
Minimum single pilot weight 54 kg 70 kg 55 kg
120 lbs 155 lbs 122 lbs
Maximum fuel weight 93 kg
205 lbs
Minimum fuel weight 9 kg 8 kg 13 kg
20 lbs 18 lbs 29 lbs

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 130l / 34
U.S. gallons. The usable fuel quantity is 124l / 33 U.S. gallons.
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
13.5V – 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.

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° for CT-LSA Australia) 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.
Autopilot
Autopilot is an optional equipment. The available autopilots are Digiflight II Series.

− CT Pilot 1 Axis, Digiflight II FP basis (Aileron, later upgrade possible);
− CT Pilot 2 Axis, Digiflight II FP basis (Aileron & Stabilizer, later upgrade possible);
− CT Pilot 2 Axis + vertical speed, Digiflight II FP VS basis (Aileron & Stabilizer with
vertical steering).
For a complete description and operating information of the autopilot see Operating
Handbook for Digiflight II Series autopilots, TruTrak Flight Systems.

CTSW Classic Light Standard Instrument Panel*
Symbolic notations
1 Ignition lock / start

2 Fuel valve
3 12V outlet
4 Switch panel
5 Flap position indicator
6 Flap circuit breaker
7 Flap switch
8 Main circuit breaker 30A
9 Main circuit breaker 25A
10 Air speed indicator
11 Three pointer altimeter
12 Circuit breakers
13 Slip & bank indicator
14 Cabin heating
15 Carburettor heating
16 Cockpit light
17 Instrument light
* - instrument panels can be chosen from the list (please see Appendix 2) with accordance to the list
of the instruments from the Customer Order

Control Quadrant
Flap position indicator
Ignition switch and starter

3.7 Carbon monoxide detector
Every CTSW aircraft (starting S/N: 07-11-21) is equipped with Carbon Monoxide (CO)
Detector.
The owner (pilot) is responsible to watch the date on the detector and when necessary –
replace it. The owner (pilot) is also responsible to mark the date when install the new one.
Condition – Color: Normal – Yellow, Caution – Green, Danger – Dark Blue.

The Quantum Eye is a multi-level Carbon Monoxide Detector. It provides a visual
indication of carbon monoxide contamination. Each detector is packaged in a protective
bag that when opened activates it. Once activated the minimum product lifetime is
18 months.
Adhesive backing allows it to be easily mounted in the cockpit or any clearly visible
surface.
Operating temperature range is from 41° to 100 ° F (5° C to 38° C), relative humidity (RH)
range from 25 to 90% RH.
Sensor Regeneration: from caution – 2 hours, from danger – 6 hours.
Note: This information is for examination only. For details please refer to the manufacturer website
www.QGinc.com.

4 Operating Limitations
4.1 Stalling speeds at maximum takeoff weight (VS1 and VS0)
VS0: 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 km/h CAS (90 km/h CAS)
VS1 Flaps 0° 42 KCAS 77 km/h CAS
VS0 Flaps 40° 39 KCAS 72 km/h CAS
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 km/h CAS

15° 80 KCAS 148 km/h CAS
4.3 Maximum maneuvering speed (VA)
VA: Design maneuvering speed (above this speed only 1/3 of max. deflection may be
given, full or abrupt deflection of the control surfaces may cause structural failure).
LSA BFU / LTF-UL BCAR Section S

registration registration registration
USA Australia
km/h kts km/h kts km/h kts km/h kts
VA, CAS 182 98 193 104 193 104 164 89

4.4 Never exceed speed (VNE)
VNE: Never-exceed speed.
LSA
registration
USA Australia
km/h kts km/h kts
2 2 1 2
VNE, CAS 268 145 301 /296 1631/1592
BFU / LTF-UL
registration
km/h kts
3
VNE, CAS 276 1503
BCAR Section S
registration
km/h kts
VNE, CAS 280 151
1 - Without rescue system;
2 - With BRS 1350 HS.
3 - With BRS 1050.
4.5 Crosswind and wind limitations

The maximum demonstrated crosswind is 30 km/h / 16 knots.
CAUTION! Due to the light operating weights and low minimum flight speeds of
Light Sport Aircraft, operations with surface winds in excess of 46 km/h /
25 kts should not be attempted.
4.6 Service Ceiling

The Service Ceiling is the maximum altitude at which a climb rate of 100 ft/min /
30 m/min can be achieved. For the CTSW it is 4,250 m / 14,000 feet.
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 maneuvering 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.
4.9 Other limitations

Flight in to known icing is prohibited.


5 Weight and Balance Information
5.1 Installed equipment list
Please see the Appendix 1.
5.2 Center of gravity (CG) range and determination
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 in. / 905 mm - the distance from the leading edge of the wing to the nose
wheel.
b: 58.07 in. / 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.
Determining the Weight and Balance
Using examples (see Appendix 3), find the loaded center of gravity location.
Using the center of gravity envelope, plot the loaded center of gravity.


6 Performance
The performance figures are based on sea level, standard atmospheric conditions and a
gross weight that depends on your local certification rules.
6.1 Takeoff distance
600 kg 472,5 kg
Take-off distance over a 15 m / 50ft obstacle 232 m / 760 ft 186 m / 610 ft
6.2 Best rate of climb

At weight 600 kg and flaps 0°: VY = 154 km/h / 78kts
6.3 Best angle of climb

At weight 600 kg and flaps 0°: VX = 122 km/h / 66 kts
6.4 Cruise speed

Propeller type: Neuform, 2 blade, 1650 mm dia.
Propeller blade incidence at 3/4*r: 27 deg
Cruise speed at 75% power

600 kg -6° (-12°) 205 km/h / 112 kts
472,5 kg -12° 205 km/h / 112 kts
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

Fuel consumption in l/h / U.S. gal/h Rotax 912 UL2 Rotax 912 ULS
at take-off performance 24,0 / 6,3 27,0 / 7,1
at max. continuous performance 22,6 / 5,6 25,0 / 6,6
at 75% continuous performance 16,2 / 4,3 18,5 / 4,9


7 Emergency Procedures
Engine failure
The first action in case of engine failure is to lower the nose and to establish best glide
speed: 115 km/h / 63 kts. 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 115 km/h / 63 kts at 15° flaps until final approach.
Before touchdown, select flaps 40°.
If there is sufficient time and the failure can be identified, an engine restart while in safe
flight altitude may be attempted.
If the restart is successful it may be possible to proceed to a suitable landing area and
perform a precautionary landing.
In case of fire shut off the engine:

• Shut off the fuel valve;
• Turn off the ignition;
• 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 its 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 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.

Failure of the Dynon EMS
Failure of the Dynon EMS (if equipped) does not directly endanger continuation of flight.
With a completely failed EMS system the engine data can no more be surveyed by the
pilot. To avoid damages to the engine the flight can be continued, but operation should
be limited to moderate RPMs (equalling maximum 185 km/h / 100 kts cruise speed at
flaps fully negative). Aerotow or banner tow shall not be done with this failure. Ongoing
flights to a qualified service station are allowed with the limitations named before.
Before such a flight due care has to be given to oil and coolant quantity checks before
the flight.
Flap control failure
If failure of the flap control occurred, proceed a suitable landing area and perform a
precautionary landing. Use instruction for the flap manual operation.
Instruction for the flap manual operation
1) To activate the manual operation of the flap control printed circuit board (PCB), do as
follows.
a) Turn the flap control switch by 180° with reference to 15° position to illuminate the
LED display VD1 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
b) When the flap control switch is turned by 180° with reference to 30° position, the
flaps start to retract (flaps move up)

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) When the movement of flaps has been accomplished, the control switch should be
reset to a neutral position (see item 1, a).
d) When the flap control switch is turned by 180° with reference to 0° 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
e) Intermediate flap position (for instance 0°, 15°, 30°) is 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, ensure 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 1, a).
2) To activate the automatic operation, set the switch in one of the designated
positions (-6° (-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 stopped automatically.
To change the settings of the automatic operation, if necessary, comply with the
instructions “Setting-up of flap positions”.


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

8. Fuel tank vent Aligned

9. Vent manifold Check
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 (follow the Rotax Manual)
10. Fuel Drain and Check
11. Static port Clear
F. Right Wing
1. Leading edge Check

2. Tie down Remove
3. Wing tip Check
4. Aileron Check
5. Flap Check
6. Fuel cap Secure
7. Fuel tank vent Aligned
8. Vent manifold Check

8.2 Engine start
1. Preflight Complete
2. Parking Brake 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. Brakes 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
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 51°C / 124°F
12. Throttle Idle
13. Flaps Set for takeoff
14. Trim Set for takeoff
15. Radios Set
16. Parking Brake Release

8.4 Normal takeoff
1. Flaps 0° to 15°
2. Throttle Full
4. Climb at MTOW:
600 kg 95 km/h / 51 kts flaps 15°
472,5 kg 78 km/h / 42 kts flaps 15°
8.5 Climb
1. Power 5500 RPM (max. continuous)

2. Best angle of climb speed Vx = 66 kts flaps 0°
3. 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 100 km/h / 54 kts
3. Flaps 15° to 40°
8.9 Normal landing
Flaps as desired, 40° for short field

Airspeed (VFE):
Flaps 0° 100 KCAS 185 km/h CAS

8.10 After landing
1. Landing light Off

2. Flaps Retract
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 procedure
Flaps 15°
Parking brake Set
Power Full
Brakes Release
Rotate 80 km/h / 44 kts
8.13 Balked landing procedure
Power Full
Flaps 15°
Airspeed 110 km/h / 59 kts
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.


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 and secured from open flame.
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. Open the top cowling hatch.
4. Open the Oil tank.
5. Turn the propeller in the direction of rotation until you hear a pronounced gurgling
sound from the oil tank. This the oil returning from the engine back to the oil tank. If you
do not complete this procedure your oil level will read low.
6. Check the oil level. If it is not sufficient, remove the top cowling and add more oil to
the tank. Be careful to not overfill.
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. Open the top cowling hatch.
4. Check the coolant level. It should be between min. and max. marks.
5. If it is not sufficient, remove the top cowling, open the cap of the coolant tank and
add coolant to fill up the tank.
6. Make sure that no air is inside the cooling system.
7. Close the coolant tank cap.
8. If necessary, add coolant to the expansion tank.
9.2 Ground handling 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.

Be careful not to damage antennas mounted on the fuselage’ bottom.

4. Push the aircraft in needed direction.
Tie down instructions
1. Attach tie down 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.
3. Stop wheels with a wheel chocks.


10 Required Placards and Markings
10.1 Airspeed indicator range markings
Aircrafts with LSA registration
Marking Speed Range

White range (flap operating range) 72 … 115 km/h 39 ... 62 kts
Green range (normal operating range) 81 [91*]..222 km/h 44 [49*]... 120 kts
Yellow range (caution range) 222 … 269 km/h 120 ... 145 kts
Red line (never exceed speed) 269 km/h 145 kts
* - with flaps in (-12º) position
Aircrafts with LTF registration
Marking Speed Range

White range (flap operating range) 72 … 115 km/h 39 ... 62 kts
Green range (normal operating range) 94 … 245 km/h 51 ... 132 kts
Yellow range (caution range) 245 … 260 km/h 132 ... 140 kts
Aircrafts with BCAR Section S registration
Marking Speed Range

White range (flap operating range) 61 … 122 km/h 33 … 66 kts
Green range (normal operating range) 74 … 219 km/h 40 … 118 kts
Yellow range (caution range) 219 … 278 km/h 118 … 150 kts
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.
* - actual for aircrafts with LSA registration only

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
Red marking 5800 RPM Tachometer

Red marking 5 bar oil pressure gauge
Red marking 130ºC oil temperature gauge
Red marking 120ºC water temp gauge (cylinder head)
Oil pressure gauge max 102 psi 7 bar

min 12 psi 0,8 bar
Throttle lever box
Choke lever box
Stabilator Trim lever box
Brakes lever box
Flaps -6° (-12°), 0°, 15°, 30°, 40° flap indicator

Oil quality Cowling hatch backside
Circuit Breakers right side of the central console
Main Circuit Breakers right side of the Central console
Fuses Switch panel (Middle Console,

depends on panel type)
Main fuses Instrument panel
Maintenance/packing interval BRS Manual & Chute placard
Baggage Compartment Baggage area
Doors External door side, under the window
Internal door side, under the window


11 Supplementary Information
11.1 Familiarization flight procedures
See the Pilot Training Supplement for familiarization procedures*.

* - actual for aircrafts with LSA registration only
11.2 Pilot operating advisories
None at this time.


12 List of amendments
Date Approved
Revision No. Affected chapters Affected pages
released by
Original Issue 28-Feb-2005
N/A N/A
1 20-Jun-2005
2 General Information 6; 8
3 Airplane and Systems
13; 14
Descriptions
4 Operating Limitations 15; 17; 19
10 Required Placards and
36
Markings
2 05-Oct-2005 4.5 Crosswind and wind
15
limitations
6 Performance 27
8.2 Engine starting 31
8.4 Normal takeoff 32

8.5 Best angle of climb
33
speed (VX); 8.6 Cruise
10.5 Miscellaneous placards
36
and markings
3 05-Apr-2006 Total revised; Name of
document changed; insert
part 12, Appendix 1, 1-62
Appendix 2, Appendix 3,
Appendix 4
4 05-Dec-06 Added “Failure of the Dynon
29
EMS” paragraph
5 30-Dec-06 Document fully revised 1 -APP3-3
5a 16-Apr-07
Oil characteristics updated 3-3
Point 3.5 carried to page 3-4 3-4

Never exceed speed values
4-2
updated
Green range for LSA
10-1
airplanes updated
5b 13-Jul-07 Corrected airspeed for US-
LSA version from 113 kts to 4-2
98 kts
List of amendments added 12-1, 12-2
6 01-Apr-08 Name of document changed i
App. 1 changed 1
App. 2 changed 2

3.1: “For the optional 3-1

engines please see
Appendix 1 (Equipment List)
” deleted
3.2: “For the optional 3-2
propellers please see
Appendix 1 (Equipment
List)” deleted
3.3: “steam blast problems 3-2
or MOGAS failing” changed
to “vapor lock or insufficient
octane on auto fuel”
3.7 Carbon monoxide 3-9
detector added
9.1: “3 to 4 times in the 9-1
direction of rotation, while
you hear the air gurgling in
the oil tank”
changed to
“in the direction of rotation
until you hear a pronounced
gurgling sound from the oil
tank. This the oil returning
from the engine back to the
oil tank. If you do not
complete this procedure
your oil level will read low.”;
“refill the oil tank”
changed to
“add more oil to the tank.
Be careful to not overfill.”
9.2: Title “Towing (moving)”
changed to
“Ground handling”;
“Install mooring”
changed to
“Attach tie down”;
“blocks” 9-2
changed to “chocks”
7 29-Apr -08 8.4 corrected 8-4

FLIGHT DESIGN Page: 1
Appendix 1. Current equipment List

The current equipment list should be inserted here. Old equipment lists should be kept
so that the history of the aircraft is properly documented. They should be marked by
hand with the word “INVALID”. The owner of the aircraft is responsible for ensuring that
a valid equipment list is available.

Appendix 2. Variants of instrument panels
Symbolic notations
1 Dynon EFIS 100 Flight information system

2 Dynon EMS 120 Engine monitoring system
3 Autopilot CT Pilot 2 Axis (Digiflight II)
4 Air Speed Indicator
5 Altimeter
6 Radio Garmin SL series & Transponder GTX series
7 Radio King KY series & Transponder KT series
8 GPS Garmin 496
9 -
10 Air speed indicator D 80mm
11 Three pointer altimeter D 80mm
12 Variometer D 57mm
13 Slip & bank indicator
14 UMA analogs (RPM meter, Oil pressure, Oil temperature,
Cylinder head water temperature, Volt meter*)
15 Hobbs hour counter
16 Trutrack ADI
* - Volt meter excluded on CTSW Classic Light ready to fly modification.

CTSW Classic Light
CTSW Classic Light base instrument panel

CTSW Classic Light additionally equipped with Honeywell Radio and

Transponder

CTSW Classic Light additionally equipped with Garmin Radio and Transponder

CTSW Classic
CTSW Classic base instrument panel

CTSW Classic additionally equipped with Autopilot, Nightflight package with

TruTrack ADI, Garmin GPS, Radio and Transponder

CTSW Advanced
CTSW Advanced (Dynon) instrument panel

CTSW Advanced additionally equipped with Autopilot, Nightflight package,

Garmin GPS, Radio and Transponder

Appendix 3. Samples of the Weight & Balance and Equipment List
Sample of the Weight & Balance and Equipment List for aircrafts with LSA registration
The acceptable empty Cg range is 9.45 to 14.17 inches.

The acceptable empty Cg range is 240 to 360 mm.

Sample of the Weight & Balance and Equipment List for aircrafts with BFU / LTF-UL
registration
The acceptable empty Cg range is 240 to 360 mm.


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Flight Design

AIRCRAFT OPERATING INSTRUCTIONS

Revision Number Revision Date Approved

List of Effective Pages

Chapter Page Revision Chapter Page Revision

Original Issue Date: 28-Feb-2005

1 Table of Contents .................................................................................................iii

Original Issue Date: 28-Feb-2005

8.13 Balked landing procedure...........................................................................8-5

Original Issue Date: 28-Feb-2005

Read this before your first flight!

Flight Design GmbH

Original Issue Date: 28-Feb-2005

Views and dimensions, inches (mm)

Original Issue Date: 28-Feb-2005

Original Issue Date: 28-Feb-2005

Page Intentionally Left Blank

Original Issue Date: 28-Feb-2005

3 Airplane and Systems Descriptions

3.1 Engine: Rotax® 912 Series

ROTAX 912 UL2 ROTAX 912 ULS

Original Issue Date: 28-Feb-2005

CTSW CTSW CTSW

3.3 Fuel and fuel capacity

Original Issue Date: 28-Feb-2005

ROTAX 912 UL2 ROTAX 912 ULS

Original Issue Date: 28-Feb-2005

3.5 Operating weights and loading (occupants, baggage, fuel, ballast)

LSA BFU / LTF-UL BCAR(S)

Original Issue Date: 28-Feb-2005

3.6 Structures and Systems Description

The movable surfaces of the CTSW are of aramid-foam-aramid, carbon-foam-aramid,

Original Issue Date: 28-Feb-2005

Rudder Trim System

BRS Parachute system

Autopilot is an optional equipment. The available autopilots are Digiflight II Series.

Original Issue Date: 28-Feb-2005

CTSW Classic Light Standard Instrument Panel*

1 Ignition lock / start

Original Issue Date: 28-Feb-2005

Flap position indicator

Ignition switch and starter

Original Issue Date: 28-Feb-2005

3.7 Carbon monoxide detector

Condition – Color: Normal – Yellow, Caution – Green, Danger – Dark Blue.

Original Issue Date: 28-Feb-2005

4.1 Stalling speeds at maximum takeoff weight (VS1 and VS0)

4.2 Flap extended speed range (VS0 to VFE)

VFE: Flaps 0° 100 KCAS 185 km/h CAS

4.3 Maximum maneuvering speed (VA)

LSA BFU / LTF-UL BCAR Section S

Original Issue Date: 28-Feb-2005

4.4 Never exceed speed (VNE)

VNE: Never-exceed speed.

4.5 Crosswind and wind limitations

4.6 Service Ceiling

4.7 Load factors

Original Issue Date: 28-Feb-2005

4.9 Other limitations