AMT-200S Maint Manual

AMT 200S
MAINTENANCE MANUAL
200-25
MAINTENANCE MANUAL AMT 200S

SECTION 1 - DESCRIPTIONS, SYSTEMS, RIGGINGS AND PLACARDS 1. Motorglider Characteristics 1.1 Basic Dimensions Wing span Wing span with winglets (optional) Wing span (wings folded) Length Maximum height 1.2 Wings Wing surface (area) Dihedral Profile Angle of incidence Wing torsion 1.3 Ailerons Percent to wing chord (depth) Aileron span Aileron surface (area) 1.4 Airbrakes Position Airbrake span Type at 45% of wing chord 4.76 ft (1.45 m) Schempp hirth on upper wing surface 30% 10.24 ft (3.12 m) 7.32 Sqft (0.68 m2) 201.29 Sqft (18.70 m2) 2 30' Naca 643618 2 -2 57.32 ft (17.47 m) 57.97 ft (17.67 m) 33.30 ft (10.15 m) 26.50 ft (8.08 m) 6.33 ft (1.93 m)
SECTION:1
1.5
Horizontal Stabilizer Horiz. stabilizer span Horiz. stabilizer surface (area) Elevator surface Horiz. stabilizer - angle of incidence 12.07 ft (3.68 m) 31.21 Sqft (2.90 m2) 10.23 Sqft (0.95 m2) -1
Page 1.1
MM - 200-25
August 10, 2004 - Rev. 8

SECTION:1
1.6
Vertical Empennage Vertical empennage surface (area) Rudder surface (area) 22.93 Sqft (2.13m2) 7.42 Sqft (0.69m2)
1.7
Landing Gear Conventional: Two main gears with a tail wheel coupled at the rudder. For ground operation the tail wheel disengages automaticaly when the minimum curve radius is reached. Main landing gear shock absorber: Pressure 130 psi ( 9,14 kg/cm2) >0C Pressure 145 psi (10,19 kg/cm2) <0C Main wheel tire: Tail wheel tire: 330 x 130 (5.00-4) pressure 45 psi (3.2 kg/cm2) 210 x 65 CR17 pressure 36.2 psi (2.5 kg/cm2) 9.18 ft (2.80 m) 16.51 ft (5.35 m)
Main landing gear track: Distance between front and rear landing gear axes: 1.8 Power Plant
ROTAX 912 S4 or 912 S2 Engine: - Maximum take-off power: 73.5 kw (99 HP) at 5800 RPM for 5 min - Maximum continuous power: 69 kw (93 HP) at 5500 RPM - Fuel - AVGAS 100 LL Octanes - Carburetor - BING type 64/32 - Magneto - ROTAX DOUBLE - ELECTRONIC - Alternator -DUCATI, 13.5 - 14.2 V/ 250 W - Starter - ROTAX 12V/0.8 HP - Oil lubricant - See recommended lubricants on page 5.21 of this manual - Oil capacity - 0.79 U.S gallons (3,0 litres) - Coolant capacity - 0.75 U.S gallons (2,8 litres);
Note: Do not use general aviation engine oil (detergent or not)
Page 1.2
July 17, 2007 - Rev. 11
MM - 200-25

1.9 Propeller Hoffmann - model HO-V62R-1/170FA 2 blades, wood core covered with fiber glass Three pitch positions: Minimum pitch, cruise pitch and feathered pitch Change from minimum pitch to cruise pitch - 3800 RPM Change from cruise pitch to minimum pitch - 2200 RPM 1.10 Cockpit
SECTION:1
- Two places - side by side - One piece canopy - longitudinal opening (slides backward) - The canopy can be jettisoned at low airspeeds but the pilot must unlock it and pushit away from the aircraft.
1.11
Seat Belts
Each seat is equipped with adjustable seat belts, which are attached to the fuselage by five points.
Page 1.3
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August 10, 2004 - Rev. 8

1.12 Air Pressure Ports
SECTION:1
1. 2. 3.
Dynamic air pressure port Static air pressure port Total energy
Page 1.4
August 10, 2004 - Rev. 8
MM - 200-25

1.13 Vent holes and drains
SECTION:1
Page 1.5
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August 10, 2004 - Rev. 8

2. Electrical Diagram
1 CHT PP1A4 ENGINE RELAY RED BLACK
ENGINE GROUND PP3A4N BATTERY 2A 2A
SECTION:1
8 PP17A22 PP18A22 4 5
PP1D10 SHUNT
PP1B10
PP2A4N PP3B10N AIRCRAFT END BUS BAR GROUND
K1
MAIN PP4A10
30A MAIN BUS BAR
PP6A20
MAIN/SOARING PP1C10 MASTER SOARING K2 SOARING PP5A10
20A
SOARING BUS BAR
PP8A20N PP7A20
BATTERY DIAGRAM
(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)
PP1A4 AMMETER/CHT
ENGINE RELAY BLACK RED 2A 2A
1 CHT 8 PP17A22 4 PP18A22 5
BATTERY
K1 MAIN PP1D10 PP1B10 PP4A10 30A MAIN
ENGINE
PP3A4N
PP2A4N
SHUNT HOUR METER
PRESSURE SWITCH E6A22
AM METER/CHT
BUS BAR GROUND
AIRCRAFT
PP6A20
+ E8A22 PP1C10 K2 SOARING
E7A22
FUSE LINE 2A
MAIN BUS BAR
MAIN/SOARING MASTER SOARING
20A PP5A10 SOARING HOUR METER SOARING BUS BAR
PP7A20 PP8A20N
+ E10A22
E9A22
SPARE 2A
BATTERY DIAGRAM
(Motorgliders s/n 200.128 to 200.132) Page 1.6
August 10, 2004 - Rev. 8
MM - 200-25

AMMETER/CHT 1 STARTER RELAY PP1A4 BLACK RED 2A 2A CHT 8 PP17A22 4 PP18A22 K1 MAIN PP1D10 PP1B10 PP4A10 30A MAIN BUS FUSE LINE 2A 5
SECTION:1
BUS BAR GROUND
BAT TERY
PP3A4N
PP2A4N FIREWALL
10A
SHUNT PP14A16 MASTER SWITCH PP6A20
HOUR METER
OIL PRESSURE SWITCH E6A22
PP8A20N PP15A16N
+ E8A22 K2
E7A22
ON BATTERY CHARGER PLUG OFF
PP1C10
MAIN BUS BAR
HOUR METER
+ E10A22
E9A22 2A
PP1A4
TO STARTER RELAY
BATTERY DIAGRAM
(Motorglider s/n 200.133 and on)
STARTER RELAY PP1A4 BLACK RED
2A 2A
BUS BAR GROUND
BATTERY
K1 MAIN PP1D10 PP1B10 PP4A10 30A MAIN BUS FUSE LINE 2A
PP3A4N
PP2A4N FIREWALL
10A
SHUNT PP14A16 MASTER SWITCH PP6A20
HOUR METER
OIL PRESSURE SWITCH E6A22
PP8A20N PP15A16N
+ E8A22 K2
E7A22
ON BATTERY CHARGER PLUG OFF
PP1C10
HOUR METER
MAIN BUS BAR E9A22 2A
+ E10A22 PP1A4
TO STARTER RELAY
BATTERY DIAGRAM
Optional Configuration Page 1.7
MM - 200-25
July 17, 2007 - Rev. 11

STARTER
SECTION:1
M
BAT TERY PP1A4 K3 KK1A4 KK5A 22 LA NDING GEAR ALARM
KK3 A20 STARTER
KK2A20
5A MAI N BUS BAR STARTER
KK6A 20N
JK3A 18 MAGNET O A
JK1A1 8 IGNIT ION A
JK2A18 IGNIT ION B JK4A 18 MAGNET O B
STARTER AND MAGNETO DIAGRAM

(Motorgliders s/n 200.119, 200.122 and on)
G G
K4
B C PP11A20 R 25V 22.000 uf E7A22 ALTERNATOR
KK3A20
30A ALTERNATOR
MAIN BUS BAR
HOUR METER
ALTERNATOR DIAGRAM
(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)
Page 1.8
July 17, 2007 - Rev. 11
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K4 PP9A10
G VOLTAGE REGULADOR G
SECTION:1
30A ALTERNATOR MAIN BUS BAR
ALTERNATOR
PP10A10
C R
5A FUSE LINE
PP13A20
25V 22.000 uf
ALTERNATOR DIAGRAM
(Motorglider s/n 200.128 and on)
PP11A20
ALTERNATOR
PP12A20N
F2A22 TURN BANK
F1A22
T&B
2A F3A22N PILOT
F11A22 TURN BANK
F10A22
T&B
2A F12A22N COPILOT MAIN BUS BAR F4A22 F3A22 GD
DIREC. GYRO F6A22N PILOT
2A
F13A22 DIREC. GYRO F15A22N COPILOT
F14A22
GD
2A
F8A22 ATT INDICATOR F8A22N PILOT
F7A22
ATT
2A SOARING BUS
F17A22 ATT INDICATOR F18A22N COPILOT
F16A22
2A
FLIGHT INSTRUMENT DIAGRAM

(Motorgliders s/n 200.119, 200.122 to 200.132)
Page 1.9
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SECTION:1
F2A22 TURN BANK (OPTIONAL) F3A22N PILOT
F1A22
T&B
2A
F11A22 TURN BANK (OPTIONAL) F12A22N COPILOT
F10A22
T&B
2A
DIREC. GYRO (OPTIONAL) F6A22N PILOT
F4A22
F3A22
GD
2A
F13A22 DIREC GYRO (OPTIONAL) . F15A22N COPILOT
F14A22
GD MAIN BUS BAR 2A
F8A22 ATT INDICATOR (OPTIONAL) F8A22N PILOT
F7A22
ATT
2A
F17A22 ATT INDICATOR (OPTIONAL) F18A22N COPILOT
F16A22
2A
FLIGHT INSTRUMENT DIAGRAM

(Motorgliders s/n 200.133 and on)
Page 1.10
July 17, 2007 - Rev. 11
MM - 200-25

LEFT GEAR MICRO SWITCH NO LEFT WING CONNECTOR
SECTION:1
GW3C22 5
GW3A22
6
GW2D22N
GW2A22N NC
GW5B22 6
RIGHT GEAR MICRO SWITCH NO
RIGHT WING CONNECTOR
GW1C22
5
GW1A22 5
GW2E22N
NC
GW5C22
6
AIR BRAKE MICRO SWITCH
NO GW2B22N GW2C22N
C GW1B22 NC
GEAR UP MICRO SWITCH
GW6A22
NO GW4A22
C GW5A22 NC
GW5D22
GW4B22 GW1B22 RIGHT GEAR DOWN LEFT GEAR DOWN
GW3B22 2A
GW12A22 GEAR LIGHT SOARING BUS GW11A22N

TEST
RETRACTED OR IN TRANSIT GW7C22
GW10A22 1
2 STARTER ENGAGED
1 LOW BATTERY
PW2A22 10 KK4A22
12 KK5A22
STARTER PW3A22N CANCEL GW7B22 2A GW7A22
13
GW9A22 2
GEAR WARN
2A PW1A22 LOW BATT PW4A22N SOARING BUS 11 9
WARNING SYSTEM DIAGRAM

(LANDING GEAR, AIRBRAKE, STARTER ENGAGED, LOW BATTERY) (Motorgliders s/n 200.119, 200.122 to 200.132) Page 1.11
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SECTION:1
LEFT GEAR MICRO SWITCH NO
LEFT WING CONNECTOR
1
C
GW3C22
5 4
GW2A22N
GW3A22
2 3
GW2D22N
GW5B22
NC
6
RIGHT WING CONNECTOR
RIGHT GEAR MICRO SWITCH NO
1
C
GW1C22
5 4 6
GW1A22
2 3
GW2E22N
GW5C22
NC
AIR BRAKE M ICRO SWITC H
NO GW2B22N GW2C22N
W A R N I N G S Y S T E M U N I T
C GW1B22 NC
GEAR UP M ICRO SWITC H
GW6A22
NO GW4A22
C GW5A22
NC
GW5D22
GW4B22 GW1B22 RIGHT GEAR DOWN
LEFT GEAR DOWN
GW3B22 2A
GW12A22
M A I N B U S
GW10A22
GEAR LIGHT
4
RETRACTED OR IN TRANSIT
GEAR LIGHT
GW11A22N
TEST
GW7C22
2
STARTER ENGAGED
1
LOW BATTERY
PW2A22
10 12
KK5A22
KK4A22
W A R N I N G S Y S T E M U N I T
STARTER PW3A22N CANCEL GW7B22
13 2
GW9A22
GW7A22
GW7C22 PW1A22
9 2A 2A GEAR WARN LOW BATT
PW4A22N
11
GN16A22 GW 13A 22 GW 15A 22
2A COOLANT LEVEL
15 7
GW17A22
8 14
SENSOR
GW18A22N
WARNING SYSTEM DIAGRAM

(LANDING GEAR, AIRBRAKE, STARTER ENGAGED, LOW BATTERY, COOLANT LEVEL) (Motorgliders s/n 200.133 and on) Page 1.12
July 17, 2007 - Rev. 11
MM - 200-25

1 3
SECTION:1
E2A22 E3A22 E1A22
OIL TEMP. SENDER
OIL TEMP./ PRESSURE INDICATOR
OIL PRESSURE SENDER
E8A22N
4 5
2A E4A22N
MAIN BUS GND BATTERY
OIL TEMPERATURE / PRESSURE DIAGRAM - Standard configuration
OIL TEMPERATURE / PRESSURE AND RPM INDICATION

Optional Configuration
2A
F1A22
TURN AND BANK (OPTIONAL)
2A
F3A22
INTERCOM (OPTIONAL)
2A
F5A22
ATT INDICATOR (OPTIONAL)
5A
VHF/COMM
B A
RV1A18 RVZA18N
VHF/COMM
3A
TRANSPONDER
B A
SN1A20 SN2A20N
TRANSPONDER
2A
ALTITUDE ENCODER
B A
JN3A22 BLACK
ALTITUDE ENCODER
AVIONICS DIAGRAM - Standard configuration

Page 1.13
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July 17, 2007 - Rev. 11

SECTION:1
Q3A18N
FUEL PUMP
Q2A18
Q1A18
5A
FUEL PUMP
PM2A20N
LEFT AUX. POWER
PM1A20
5A
AUX. POWER PM2B20N RIGHT AUX. POWER PM2B20
AVIONICS DIAGRAM - Standard configuration
Q4A22 DB15
2A
FUEL INDICATOR RED YELLOW BLACK SENDER LEFT
1 1
FUEL LEVEL INDICATOR
Q5A22 Q7B22N Q7A22N DB15
Q4C22 Q5B22 Q7E22N
1 2 3
2 3
3
Q6A22
1 2 3
Q4E22 Q6B22 Q7E22N
RED 1 2 3 YELLOW BLACK SENDER RIGHT
FUEL LEVEL DIAGRAM - Standard configuration
FUEL LEVEL DIAGRAM

Optional Configuration
Page 1.14
July 17, 2007 - Rev. 11
MM - 200-25

3. Ground Connecting Straps
4 5 4 5 4
SECTION:1
4 6
5 4 3
2 1
4 2 4 5 4
STRAP IPC REFERENCE
PAGE 2.16 2.44/2.45/2.46/2.47/2.48 2.58 2.62 2.68 2.74
ITEM 2-3-43-66 18-26-44-90 19-26 3-26-33-60 11-27 66
6
1 2 3 IPC FIGURE 05 IPC FIGURE 13 IPC FIGURE 15 IPC FIGURE 16 IPC FIGURE 18 IPC FIGURE 20
2
4 5 6
Ground Connecting Straps Table
Page 1.15
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July 17, 2007 - Rev. 11

4. Fuel System Each wing has one aluminum fuel tank located between the leading edge and the main gear wheel well. The tanks are independent and the fuel level is indicated by a fuel quantity transmitter. There is a three-position selector valve to select the tank in use and cut off the fuel.
USABLE Left Wing Tank Right Wing Tank Total Capacity 11.62 US gallons (44 litres) 11.62 US gallons (44 litres) 23.24 US gallons (88 litres) TOTAL 11.89 US gallons (45 litres) 11.89 US gallons (45 litres) 23.78 US gallons (90 litres)
SECTION:1
Find the fuel system components below.
123456789-
Tank cap and vent (breather) Drain valves Left fuel tank 11.89 U.S gallons (45 liters) Right fuel tank11.89 U.S gallons (45 liters) Fuel tubes and connections Electric fuel pump Carburetor Mechanic fuel pump Fuel filter
10- Three position fuel selector valve
Page 1.16
August 10, 2004 - Rev. 8
MM - 200-25

SECTION:1
4 5 5
10 2 5 5
2
6 5
FIREWALL
5 9
FUEL RETURNING LINE TO FUEL TANKS
7
CARBURETOR VENT AND DRAIN TUBE
Fuel System
Page 1.17
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August 10, 2004 - Rev. 8

5. Brake System 5.1 Find below the basic components of the brake system. 12345675.2 5.3 5.4 Fluid reservoir Master cylinders Tubes Fittings Flexible tubes Brake cylinder Bleeder valve
SECTION:1
Only use approved brake fluids: Aeroshell Fluid 41 or Esso HD 400. Measure brake lining thickness (minimum 0.100 inches). Follow the procedure below to bleed the brake lines if required. - Push the brake pedals three times and keep the pedals pressed; - Open the bleeder to remove all air bubbles from the brake lines; - Close the bleeder when all air is removed; - Examine brake pressure again by pressing the pedals.
5.5
Follow the same procedure for the other pedals.
Page 1.18
August 10, 2004 - Rev. 8
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SECTION:1
Brake System
Page 1.19
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August 10, 2004 - Rev. 8

6. Aileron Controls 6.1 Find below basic components of the Aileron Control System 123456789Control Stick Aileron rod n 1 Aileron rod n 2 Aileron rod n 3 Aileron rod n 4 Aileron link rod Inboard and outboard ailerons Bellcrank n 1 Bellcrank n 2
SECTION:1
10- Bellcrank n 3 11- Articulated connecting rod 6.2 Follow the procedure bellow to rig the ailerons if required
6.2.1 Put the elevator in neutral position and install the tool P/N 55400-A-28 F1 on the horizontal stabilizer to lock it. 6.2.2 Put the control stick in neutral position and install the tool P/N 27100 D/E-A-28 F1 on the left side of the cabin to lock the control stick. 6.2.3 Using the wing trailing edge as the neutral reference (zero degree) put the protactor over the mid section of left and right ailerons and measure the aileron neutral position. 6.2.4 Adjust the aileron neutral position by regulating the aileron link rod n 6 (P/N 27112IPC fig. 13 D item 60) to 1 (one) degree downward on the two ailerons.
Page 1.20
August 10, 2004 - Rev. 8
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6.2.5 Record the neutral position in a table as the example below
AILERON (LH) Neutral Up Down AILERON (RH)
SECTION:1
(+ 1)
(+ 1)
6.2.6 6.2.7
Release the control stick by removing tool P/N 27100 D/E-A-28 F1. Move the control stick to full left and measure the travel on the two ailerons. Record the values in the table shown above. Note: Make sure that the left stop-screw P/N TH-5x25-RT (ref. IPC fig. 15 item 6), located at the control stick basement is being not the primary stop. The primary stop must be in the left bellcrank n 3
6.2.8
Move the control stick to full right, measure the travel on the two ailerons and record values. Note: Also inspect if the right stop-screw located at the control stick basement is not the primary stop. The primary stop must be in the right bellcrank n 3.
6.2.9
Compare the values measured to the specified parameters below.
AILERON (LH) Neutral Up Down 0 1 15 1 15 1
AILERON (RH) 0 1 15 1 15 1
Page 1.21
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August 10, 2004 - Rev. 8

SECTION:1
6.2.10 If the travel limits measured do not agree with the specified parameters, continue the rigging procedure. 6.2.11 Move the control stick to full left; adjust the up-position of the left aileron by regulating the up-stop screw P/N TH-5x25-RT (ref. IPC fig. 13 D item 51) on left wing and measure the travel on the two ailerons. Compare values to the specified travel parameters and adjust the left up-stop again if the right aileron down-position is beyond the limits. Note: If it is impossible to put the right aileron on the down position within limits, stop adjusting the left up-stop screw and continue the procedure in the right wing.
6.2.12 Move the control stick to full right; adjust the up-position of the right aileron by regulating the up-stop screw P/N TH-5x25-RT (ref. IPC fig. 13 D item 51) on right wing and measure the travel on the two ailerons. 6.2.13 Compare values to the specified travel parameters and adjust the right upstop again if the left aileron down-position is beyond the limits. Note: If it is impossible to put the left aileron down-position within the limits, stop adjusting the right up-stop screw.
6.2.14 If the aileron travel (up and down position are within the limits, the rigging procedure is complete and satisfactory. Tighten all adjusted bolts, nuts and lockwashers and apply torque seal. 6.2.15 If the up-position of one aileron is at the maximum travel limit (16) and the down-position of the opposite aileron is less than the minimum limit (14), disconnect the control rod P/N 27101 (ref. IPC fig. 13 A item 2) in the right and left landing gear wells and increase the rod length by turning the fork turnbuckle rod one turn counterclowise on each control rod. 6.2.16 Repeat all the rigging procedure again starting on item 6.2.1
Page 1.22
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SECTION:1
Aileron Controls
Page 1.23
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August 10, 2004 - Rev. 8

7. Elevator Control System 7.1 Find below basic components of elevator control system. 123456789Control stick Rod n 1 Rod n 2 Rod n 3 Rod n 4 Bellcrank n 1 Bellcrank n 2 Bellcrank n 3 Bellcrank n 4
SECTION:1
10- Elevator Assy 7.2 Rigging the elevator.
7.2.1 Remove the horizontal console inside cockpit 7.2.2 Make sure that the stop screws P/N TH-5x25-RT and TH-5x40-RT (ref. IPC fig. 15 itens 6 and 7) are not damaged. Replace them if necessary. 7.2.3 Put the elevator in neutral position and install the tool P/N 55400-A-28 F1 on the horizontal stabilizer. 7.2.4 Install a protactor on the elevator and adjust it to zero degree. 7.2.5 Remove tool from the horizontal stabilizer and measure the travel on the elevator. 7.2.6 Adjust the up and down position as required by regulating the stop screws P/N TH5x25-RT and TH-5x40-RT referenced above. See elevator control surface travel on section 3.
Page 1.24
August 10, 2004 - Rev. 8
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SECTION:1
Elevator Control
Page 1.25
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August 10, 2004 - Rev. 8

8. Rudder Control System 8.1 Find below the basic components of the Rudder Control System 12348.2 Rudder pedals Control cables Rudder bellcrank Rudder
SECTION:1
Rigging
8.2.1 Inspect the travel to the left and right sides by adjusting the limiting stop screws on each side of the bellcrank arm. See rudder control surface travel on section 3. 8.2.2 Make sure that bolt nuts are correctly tightened and the stop screws are not damaged.
Page 1.26
August 10, 2004 - Rev. 8
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SECTION:1
Rudder Control
Page 1.27
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August 10, 2004 - Rev. 8

9 Elevator Trim Control System 9.1 Basic components of the Trim Control System: 1234569.2 Trim control wheel assembly Trim tab wheel indicator Cartridge spring Elevator control rod Cable assembly support Cable
SECTION:1
Rigging
9.2.1 Verify the elevator travel (up and down) and adjust as necessary. See item 6. 9.2.2 Install tool n 55400-A-28F1 at the horizontal stabilizer to lock the elevator in the neutral position. 9.2.3 Check if the indicator of trim control at the horizontal console is in the neutral position. Remove the console and adjust the indicator position at its fitting. 9.2.4 Remove tool n 55400-A-28F1 at the horizontal stabilizer and verify the elevator trim travel of indicator; full forward - nose up, full rearward - nose down, adjust limiting stops if necessary. 9.2.5 Verify the cable tension (25 lb 2 lb); adjust cable tension on turnbuckcle as necessary; make sure that bolts are correctly tightened.
Page 1.28
August 10, 2004 - Rev. 8
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SECTION:1
Trim Control System

Page 1.29
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August 10, 2004 - Rev. 8

10. Airbrake Control System 10.1 Basic components 12345610.2 Airbrake control lever Airbrake control link rod Airbrake angular transmission gear box Airbrake push rod Airbrake torque tube (rod) Airbrake housing
SECTION:1
Rigging (1) (2) Extended: Retracted: Inspect the correct airbrake extension by adjusting the stop screw at the base of the control lever below the center console. Inspect the airbrake locking and its opening by adjusting the length of the push rod (fig. 2 item 4) located in the airbrake. The airbrake height must be the same for the two wings and the airbrakes must open simultaneously
Measure the extended airbrakes near the wing root, from the upper wing surface to the upper airbrake surface. The height must be 6.38 in 0.31 in (162 mm 8 mm) (3) Adjusting the Micro Switch (See figure 2) 123Keep airbrakes retracted and locked. Approach the micro switch to the airbrake control lever until activate micro switch is depressed. Tighten the micro switch in this position.
Page 1.30
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SECTION:1
Airbrake Control System Figure 2

Page 1.31
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August 10, 2004 - Rev. 8

SECTION:1
Figure 2
12345-
Airbrake control lever Center console Airbrake control link rod Stop screw Airbrake micro switch
6.38 0.31 in
Figure 3
Page 1.32
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SECTION:1
This page intentionally left blank
Page 1.33
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August 10, 2004 - Rev. 8

11. Main Landing Gear Control System 11.1 Basic components 12345678Landing gear control lever Landing gear control rod Landing gear torque tube Landing gear gear box Link rod Control arm Rod Landing gear assy
SECTION:1
Page 1.34
August 10, 2004 - Rev. 8
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SECTION:1
Main Landing Gear Control System

Page 1.35
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August 10, 2004 - Rev. 8

11.2 Main Landing Gear Rigging
SECTION:1
11.2.1 Put the aircraft on jacks 11.2.2 Landing Gear Up-Lock Rigging (See Figure below) (a) (b) Retract the landing gear Adjust the length of the link rod (1) on the rod ends until you obtain an effective landing gear uplock Extend and retract the landing gear several times. Note: Do the procedure above for the two main gears.
(c)
1234-
Link rod Compensation Spring Rod Crank
5678-
Control Arm Stop screw Landing gear leg (fixed strut) Wing spar
Page 1.36
August 10, 2004 - Rev. 8
MM - 200-25

11.3 Landing Gear Down-Lock Rigging (See Figure below) Press the landing gear to the opposite direction of its retraction (1) Adjust the stop screw (6) of the control arm (3) until it aligns with the rod (5) WARNING: MAINTAIN THE LANDING GEAR EXTENDED BY MEANS OF THE FORK BECAUSE THE COMPENSATION SPRING CAN INADVERTENTLY CLOSE THE GEAR. (2) Turn the stop screw (details item 6) 2.5 turns clockwise and lock it with the lock nut to obtain the correct rigging position.
SECTION:1
Detail A 12345Link rod Compensation Spring Control Arm Gearbox control lever Rod 67891011Stop screw Landing gear leg (fixed strut) Wing spar Landing gear fork Locking mechanism Micro switch
Page 1.37
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August 10, 2004 - Rev. 8

SECTION:1
11.4
Landing Gear Control Lever Rigging - (See figure below) Do the rigging procedure with the landing gear retracted. (1) Adjust the length of the control link rod (2) so it does not pass the upper dead center as it is shown in the figure below, forming at maximum an angle of 175 between the rod and the torque tube cranck. Tighten the nut of the control link rod and lock it using a lock washer.
11.4.1
(2)
12345Page 1.38
Landing gear control lever Landing gear control link rod Landing gear torque tube Retracted landing gear micro switch Center console
August 10, 2004 - Rev. 8
MM - 200-25

11.5 Adjusting of Landing Gear and Airbrake Warning Devices (See Figure in the Preceeding Page) Note: Before performing the adjustment, check the correct attachment of the airbrake micro switch. 11.5.1 Retracted landing gear- warning micro switch rigging
SECTION:1
(a) Extend the airbrakes (b) In the landing gear up and locked position, approach the micro switch to the landing gear control lever until the warning is activated. (c) Tighten the micro switch in this position. 11.5.2 Extended landing gear-down warning micro switch rigging
(a) Maintain the airbrakes extended (b) In the landing gear down and locked position, approach the micro switch to the upper articulated strut of the landing gear until the warning horn stops. (c) Tighten the micro switch in this position. Do the operations in 1 and 2 for the other landing gear. 11.5.3 Extended airbrake- warning micro switch rigging
(a) Extend the airbrakes (b) In the landing gear up and locked position, approach the micro switch to the airbrake control lever until the warning is activated. (c)Tighten the micro switch in this position. 11.6 Checking the Landing Gear Operation. 11.6.1 Operate the landing gear retraction for several times to assure the following: ln the up position make sure that the individual gear is positively locked by pulling the gear down. The control lever must have some resistance after unlocking from the up position.
Page 1.39
MM - 200-25
11.6.1.1
11.6.1.2
August 10, 2004 - Rev. 8

11.6.1.3 The lever must show positive sign of locking in the down position (backwards). Make sure that each upper articulated strut does not let the landing gears retract Make sure that all rod lock nuts are tightened and locked. The warning must sound in the following situations: Landing gear in transit and airbrakes extended or retracted. Landing gear up and airbrakes extended. CAUTION:
SECTION:1
11.6.1.4
11.6.1.5 11.6.2 11.6.2.1
Inspect the operation of the warning silencing switch with the airbrakes extended and the landing gear up or in transit. 11.6.2.2 11.6.2.3 11.7 Inspect all safety pins or wires of the rods; (eliminate all or eventual interferences which permit the lock nuts and threaded parts to unscrew). Inspect the correct attachment of the micro switches.
Main Landing Gear - Movable Strut Removal 11.7.1 11.7.2 11.7.3 11.7.4 11.7.5 11.7.6 11.7.7 11.7.8 Put the aircraf on jacks, without touching the ground, and use a toil weight to avoid aircraft forward drop from jacks. Release the gas pressure from the shock absorbe. Remove the brake cylinder assembly. Remove the landing gear lower cover. Keep the wheel supported by a block. Release the torque links by removing its screw. Remove the plate (flange) by releasing the screws. Proceed the block release and remove the movable landing gear strut.
12. ldentifying the Main Components The serial number of each main component permits to identify the correspondent Manufacturing Control Sheet which was used during manufacture of the component. The serial number can be found in the Final Inspection Report, furnished for each aircraft and in the identification placard attached to each component.
Page 1.40
August 10, 2004 - Rev. 8
MM - 200-25

SECTION:1
ln order to identify the main subassemblies of the motorglider AMT-200S Super Ximango, refer to the table below:
Page 1.41
MM - 200-25
November 23, 2004 - Rev. 9

SECTION:1
This page intentionally left blank
Page 1.42
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 1
13.
Placards
25-B 24 30-B 32 23 21-A 22 5-A
19
47
31
16
27
4 17 29
34 18 36
28
16
35 6 8
2 1
33 10 9 11
Standard version
25 24 30 22 32 5 19
31
21
21
16
27
4 17 29
34 18 36
28
16
35 6 8
1 23
33 10 9 11
Optional - Factory Incorporated Only

Page 1.43
MM - 200-25
August 10, 2004 - Rev. 8

25C 24 30 19 43 32 44 45 3 27 4 17 29 21A 23 31 44 22 5 34 18 36 46
SECTION: 1
35 6 8
33 10 9 11

25D 24 30-B 19 43 32-B 23 44 45-B 3 27 4 17 29 21-A 5-A 34 18 36 22 31 48 47 44 46
35 6 8
33 10 9 11

Page 1.44
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 1
25-E 24 30-B 19 31 32-C

-A A 521
22
23
23
21
5A
-A
27
4 17 29
18
36
34
35
6
33 10 9 11

25-G 24 30-B 19 31 32-E
21
22 38
5A
23
23 A 5-
-A
21 -A
27
4 17 29
34 18 36
35 6 8
33 10 9 11

Page 1.45
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 1
25G 24 30-B 19 43-A 44-A

AIR FRAME TIME
31 21-A 32-E 5-A 23 22 44-A
ENGIN TIME E
48-A
27
4 17 29
18
36
34
35 6 8
33 10 9 11

25H 24 30-B 19 31 44-A 21-A 3 32-E 23 22 5-A 43-A 44-A 47
27
4 17 29
18
36
34
48-A
35 6 8
33 10 9 11

Page 1.46
October 10, 2005 - Rev. 10
MM - 200-25

SECTION: 1
25-I 22 38 30-B 19 31 32-F

21
5A
24
23
-A
23 21
5A
-A
27
4 17 29
34 18 36
35 6 8
33 10 9 11

2 5 -J
22 3 0 -B
24
19
43-A 31 3 2 -G 44-A
21 -A
44-A 49 39 37 51
5A
23
49 39 37
23
50
21
5A
-A
27
4 17 29
34 18 36
35 6 8
33
10 9
11

Page 1.47
MM - 200-25
October 10, 2005 - Rev. 10

25-K
SECTION: 1
22 30-B 38 32-H
24 19
21-A
23
3
5-A 27 4 17 29 34 18 36
35 6 8
33
10 9
11

25-L 22 24 43-A 30-C 44-A
21
48-D 3 27 31 36 34 32-I
44-A
5A
23
-A
23 21
5A
-A
4 17 29 35
18
2 6 8
1 33
10
9 7 11

Page 1.48
July 17, 2007 - Rev. 11
MM - 200-25

SECTION 5 - MAINTENANCE CHECKS 1. External Visual Inspection Inspect the aircraft before every flight to prevent failures or even accidents. 1.1 External Inspection (1) Cabin
SECTION: 5
- Extend the airbrakes. - Make sure that the ignition switch OFF. NOTE We recommend that you do the inspection clockwise from the trailing edge of the left wing root. CAUTION Make sure there are all yellow bolt torque seals. (2) Left Wing Examine the airbrakes for the condition and plays. Examine the aileron for condition, freedom of movement and plays. Examine the wing folding mechanism for general condition, plays and fairing attaching points. Examine wingtip for condition. Examine tire for proper inflation, cust and slippage. Examine leading edge for condition. Examine the areas between the inborad and outboard wings and the wing root and fuselage for correct clearance. Examine pitot tube for condition, cleaning and obstructions. Make sure that the access panel is correctly attached. Examine landing gear for the condition of the leg, strut, damage and shock strut. Make sure that fuel tank caps are correctly closed. Examine the lower wing surface for leakage. Examine fuel tank drain for leakage.
(3) Power Plant - Examine propeller and spinner for condition. - Make sure that the cowlings are correctly attached and not damaged.
Pgina 5.1
MM - 200-25
Agosto 10, 2004 - Rev. 8

- Make sure that engine cooling openings are clear. - Examine oil level. - Drain fuel filter. For more information, refer to engine and propeller manuals. (4) Right Wing - Do the same procedure used for the left wing except for the pitot tube. (5) Fuselage - Examine the fuselage for the condition. - Make sure that the static pressure port is clean and clear. (6) T-Tail Make sure that the total pressure port is clean and clear. Examine rudder for freedom of movement, plays. Examine rudder cables for condition. Examine rudder linkage. Examine elevator for freedom of movement and plays. Examine horizontal stabilizer for condition and plays. Examine the tail wheel leg, shock strut, anti-shimming for condition. Examine tire for condition, inflation and slippage. Make sure that the wheel is correctly distant from the fuselage (minimum 1 inches and normal 2 inches).
SECTION: 5
(7) Canopy Examine canopy for cracks, scratches and clean. Make sure that the canopy rail is clean and correctly attached. Examine attaching pings for wear and blockages. Make sure that the latching pins are corectly aligned with the front hole.
(8) Cabin Interior Examine seat belt buckles for condition. Make sure that the seat belt straps are correctly attached to the fuselage. Examine flight controls for correct response. Examine throttle, propeller and mixture levers for correct response.
Pgina 5.2
Agosto 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
Examine pedals for condition. Examine rudder cables for condition. Examine panel instruments for general condition. Make sure that the airbrakes retract and extend symmetrically and lock correctly.
2. Maintenance Inspection Guideline The inspection procedures are shown on Scheduled Inspection tables. The scheduled inspections cover the following groups: a. operational inspection b. control cabin c. fuselage d. wings e. stabilizers f. landing gear g. propeller h. power plant i. engine test run j. leveling and weighing k. general The scheduled inspections are organized as follows: - column inspection: corresponds to the inspection or procedure you must to do; - columm period: corresponds to the inspection period. The inspections are divided into the intervals, as follows, first 25, 50, 100 and 200 flight hours and 1 year. - symbol X corresponds to the inspection or operation required at the corresponding interval. The ROTAX 912 S4 or 912 S2 engine must be overhauled every 1200 hours or 1500 hours depending its serial number, or 10 years whichever comes first. (See ROTAX Service Bulletin n 912-041 to select the TBO according to engine serial number). The HOFFMANN PROPELLER HO-V62R-1/170FA must be overhauled every 1500 hours or 7 years whichever comes first. (See HOFFMANN PROPELLER Service Bulletin n E1 to verity TBO progression). Only authorized workshops can adjust the engine and propeller. For more information on engine and propeller maintenance, refer to the corresponding manuals.
Pgina 5.3
MM - 200-25
July 17, 2007 - Rev. 11

SECTION: 5
FIRST OPERATIONAL ITEM INSPECTION

NOTE: Before checking oil level, turn propeller over several times to ensure that crankcase oil has been returned to the oil tank.This process finishes when air is returning back to the oil tank and can be noticed by a murmur from the open oil tank. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Do engine run-up and record all engine parameters. Check electric and engine-driven fuel pumps and fuel tank selector. Check fuel quantity and recalibrate fuel system, if necessary. Check alternator output. Check carburetor heat air control. Check parking brake. Check gyro instruments for noise and roughness (if applicable). Do the ignition check. Check throttle for correct operation. Check engine idle speed. Check eletronic equipment for operation. Ground ignition circuit. Check flight controls, trim control and air brake for freedom of movement and correct deflection. Check pedals for position detents and brake operation. Check canopy locking mechanism from inside and outside. Check pilot's reports in the log book. X X X X X X X X X X X X X X X X X X X X X X X
EVERY 50 h 100 h 200 h 1 year
25 h
X X
X X X
X X X
X X X X
X X X X X X X X X
X X X X X
X X X
Page 5.4
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST CONTROL CABIN ITEM

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Check seats, seat belts, shoulder harness and parachutes (if applicable) for condition and wear. Check cabin airflow inlets. Check hot air ducts for leaks. Make sure the hot air valve closes correctly. Check pitot and static lines for security, condition and leaks. Make sure that the total pressure filter is clean. Inspect panel instruments for correct attachment, markings and placards. Inspect the artificial horizon, directional gyro for correct attachment and condition (if applicable). Check compass correction card. Recalibrate the compass. Inspect internal illumination and instrument panel illumination (if equipped). Inspect navigation lights, anti-collision lights and landing light (if installed). Check fire extinguisher. Check internal placards. Check identification plate. Check air brakes for RETRACTED, EXTENDED and intermediate positions. Make sure that the two air brakes move symmetrically. NOTE: If the air brakes do not move symmetrically, contact AEROMOT for more instructions. X X X X X X
EVERY 50 h
X X X
25 h
100 h
X X X X
200 h
1 year
X X X X X
X X
X X X X
X X
X X X
X X
Page 5.5
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST CONTROL CABIN ITEM

16. 17. 18. 19. Check cables and connections located under control column fairing. Make sure there are spare fuses available. Check the spar attaching pin for deformation, cracks , corrosion and plays. Perform instrument calibration test for the altimeter, speed indicator and vertical speed indicator .
EVERY 50 h
X X X
25 h
100 h
X X X
200 h
1 year
X X X X
Page 5.6
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST FUSELAGE ITEM

1. 2. Remove baggage compartment inspection panel. Inspect rear fuselage for condition. Also check the items, as follows: - antennas - cables - rudder control - elevator control rods - bellcranks - ground cables 3. 4. 5. 6. 7. 8. 9. Install baggage compartment inspection panel. Inspect external surface for deformation and cuts. Check canopy for cracks, deformation and sealing. Check canopy side locks for condition. Lubricate rails. Inspect external placards. Check drain holes and static ports for obstruction. Clean holes and ports, if required. Inspect optional equipment attaching points and supports. X X X X X X X
EVERY 50 h
X X
25 h
100 h
X X
200 h
1 year
X X
X X X X X X X
X X X X X X X
Page 5.7
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST WINGS ITEM

1. 2. 3. 4. 5. 6. 7. 8. Check wing surface for condition, deformation, corrosion, wear and cracks. Check lights for condition and cracks. Remove access panels on the outboard wings Inspect the pitot tube for condition and security. Make sure it is clear. Remove wing/ fuselage adhesive tape. Make sure that flight control cables are clear in the wing folding area. Inspect wing spar ends for damage. Check wing folding mechanism for condition, corrosion and wear. Make sure it locks correctly. Lubricate, as necessary. Check surface drain holes for condition and obstructions. Check ailerons for chafing, unusual noise, deformation and plays; check vent holes for condition and obstructions Inspect aileron support and bellcranks for lubrication and condition. Check aileron control rods for chafing, routing and travel limits. Check aileron attaching bearings for axial and radial plays. In case you find plays, repair as necessary. Inspect wing/fuselage attachment for plays. Inspect wing surface near the landing gear for deformation and corrosion.
EVERY 50 h
X X X X X X X X
25 h
100 h
X X X X X X X X
200 h
1 year
X X X X X X X X
9. 10.
X X
X X
X X
11. 12. 13. 14. 15.
X X X X X
X X X X X
X X X X X
Page 5.8
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST WINGS ITEM

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Inspect wing fairings for cracks, corrosion and deformation. Operate air brakes. While extending the air brakes, inspect Inspect fuel tank cap gasket for deterioration. Make sure that fuel tank cap vent is clear. Check fuel lines for leaks and wear. Drain fuel tanks. Remove fuel sump. Clean fuel strainer. Internally inspect fuel tanks for corrosion. Clean fuel tanks, if required. Install new adhesive tape. Install access panels. X X
EVERY 50 h
X X X X
25 h
100 h
X X X X
200 h
1 year
X X X X X X X X
X X
X X
Page 5.9
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST STABILIZER (HORIZ. AND VERT.) ITEM

01. 02. 03. 04. 05. 06. 07. 08. 09. Remove access panel on vertical stabilizer Inspect surfaces for deformation, wear and cracks. Check elevator vent holes for condition and bstruction. Check flight control travel limits and deflections. Check lights for condition, security and cracks. Check horizontal stabilizer for plays and correct torque of the attaching screw . Lubricate elevator and rudder rod ends. Check elevator control rod for chafing, routing and travel. Check elevator trim for chafing, freedom of movement and travel. Compare the positions of the surface and the indicator. Check vertical stabilizer supports and bearings for corrosion. Check rudder attach points; check rudder vent hole Check rudder attaching nut for correct torque. Use a 10x glass to inspect rudder axles and spherical bearings for deformation, cracks, wear and plays. Check rudder control cables and nicopress sleeves. Install access panel. Make sure that total energy tube is clear. if in use. X X X X X X X X
EVERY 50 h
X X X
25 h
100 h
X X X
200 h
1 year
X X X X
X X X X X
X X X X X
10. 11. 12 13. 14. 15. 16.
X X X
X X X X X X X
X X X X X X X
Page 5.10
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST LANDING GEAR ITEM

01. 02. Put aircraft on jacks. Put an assistant in the control cabin. Ask this person to extend and retract the landing gear while you make sure that the wheels fit correctly into the wheel well. The covers must also close correctly. NOTE: If the landing gear legs do not retract symmetrically, there is a malfunction on the angular gear box and you must contact AEROMOT for more instruction. 03. Remove the central console and make sure that the landing gear control handle fits correctly in the EXTENDED and RETRACTED positions. Inspect landing gear uplock microswitch and air brakes warning microswitch Inspect downlock microswitch. Check landing gear warning system. Check shock struts for corrosion, correct travel and leakage. CAUTION: In case of leakage, disassemble shock strut using the tool P/N 35350-A-23 because of the compressed internal spring and replace oil leaking o'rings. 08. 09. 10. 11. Inspect landing gear legs, torque links, drag brace and downlock for corrosion, cracks and proper attachment. Calibrate shock struts, if required. Inspect tires for wear, cuts, pressure leakage and slippage. Remove the wheels and inspect the sealed bearings for wear. CAUTION: Do not put and clean the sealed bearings into hydrocarbon solvents. X X X X
EVERY 50 h
X X
25 h
100 h
X X
200 h
1 year
X X
04. 05. 06. 07.
X X X X
X X X X
X X X X
X X X X
X X X X
Page 5.11
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST LANDING GEAR ITEM

12. Inspect wheels for cracks using a 10x glass. NOTE: In case of hard landing or 500 flight hours, inspect wheels with penetrant. 13. 14. 15. 16. 16. 17. 18. Inspect brake linings and discs for wear, distortion and deformation. Check brake fluid level. Inspect brake hoses for leaks, condition and security. Remove tail wheel and check it and the strut for condition, security and free movement. Inspect tail wheel springs. Lubricate tail wheel. Remove aircraft from jacks. X X X X X X
EVERY 50 h
X
25 h
100 h
X
200 h
1 year
X
X X X
X X X X
X X X
X X X
Page 5.12
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST PROPELLER ITEM

01. 02. 03. 04. Remove spinner Inspect spinner and plate for cracks, deformation and attaching hole wear. Inspect propeller attaching nuts. Torque the nuts to 390-410 in.lb. and apply the torque seal. Use a magnifying glass to check propeller blades for vibration spots, wear and cracks. Repair the propeller according to the Propeller Manual ( if required). Check for smooth turning of the blades. Slightly grease the four pitch change rods of the outside pitch change mechanism where they slide into the bushings. Clean and grease thrust plate slightly. Check visible hub parts for cracks and corrosion. Check screws and lockwires. Check counterweights for correct position. Make sure that the metal ferrule is correctly sealed with silicone rubber material. Check pitch change cable for condition. Install spinner NOTE: Overhaul the propeller every 1500 flight hours or 7 years whichever comes first. X
EVERY 50 h 100 h
X X X X
25 h
200 h
1 year
X X X X
05. 06.
X X
X X
07. 08. 09. 10. 11. 12. 13.
X X X X X X X
X X X X X X X
Page 5.13
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST POWER PLANT ITEM

01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. Remove engine cowling. Inspect frame 1 and firewall for deformation, cracks, corrosion and security. Check battery gravity and electrolyte level. Clean battery terminals and check electrical wires. Remove battery. Check battery box for acid leakage. Make sure that batterybox drain is clear. Make sure that the cell filler caps close correctly. Inspect the electrical box. Check electrical wiring, fuses, relays and capacitor for wear and interference. Inspect alternator connectors for security and corrosion. Check power plant cables for condition and security. Inspect starter for condition and corrosion. Inspect the engine for damage and abnormalities. Inspect cooling air ducts, baffling and cylinder cooling fins for obstructions, cracks, wear and condition. Take note of temperature influence. Inspect temperatures and pressure sensors for security and condition. Inspect all coolant hoses for damage, leak, hardening from heat, porosity, loose connections and secure attachments. Verify routing for kinks and restricted elbows. Inspect the leakage bore at the base of the water pump for signs of leakage. X X
EVERY 50 h
X X X X X X X X X X X X X X
25 h
X
100 h
200 h
1 year
15. 16.
X X
X X
X X
X X
17.
Page 5.14
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST POWER PLANT ITEM

18. Inspect the expansion tank for damage and abnormalities. Verify coolant level, fill as necessary. Check radiator cap. Inspect rubber plate on expansion tank base for secure fit. Inspect and clean the low level sensor of expansion tank Inspect the overflow bottle for damage and abnormalities.Verify coolant level, replenish as necessary. Check line from expansion tank to overflow bottle for damage, leakage and clear passage. Verify venting bore in cap of overflow bottle for clear passage. Inspect all oil hoses for damage, leak, hardening from heat, porosity, security of connections and attachments. Verify routing for kinks or restricted elbows. NOTE: Hose service life is 5 years. Inspect all fuel hoses for damage, leakage, hardening from heat, porosity, secure connections and attachments. Verify routing for kinks or restricted elbows. NOTE: Hose service life is 5 years. Inspect engine mounts and fasteners for secure fit, damage from heat, cracks and deformation. Check attachment screws and nuts of all external parts for security and fit. Check safety wiring, renew as necessary. Check the backlash. Check the friction torque. Record Actual Friction Torque See Rotax Maintenance Manual Remove oil drain screw from oil tank. Drain old oil and dispose as per environmental regulations. Remove oil filter from engine and install new oil filter.Lubricate mating sealing ring of new oil filter with engine oil. Screw on new filter by hand. Cut oil filter housing without producing any metal chips and inspect filter mat. X X X X X X
EVERY 50 h
X
25 h
X
100 h
X
200 h
1 year
X
19. 20.
X X X
21.
22.
23. 24.
X X
X X
X X
X X
25. 26. 27. 28.
X X X X
29.
Page 5.15
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST POWER PLANT ITEM 25 h

Renew gasket ring of drain screw on oil tank.Fit drain screw and tighten to 25 Nm (220 in.lbs.). Refill oil tank with approx. 3 litres of oil. For oil quality refer to Operator's Manual and Service Information ROTAX SI-912-016 / SI-914-019. Flush the coolant system. Inspect the air filter. Do the carburetor synchronization check. Mechanical or pneumatic synchronization. Checkthe float chamber venting. Check venting lines for condition, secure attachment, clear passage and routing for kinks and restrictions. Check free movement of the carburetor activation (throttle lever and starting carb). Remove and install the carburetors in the course of carburetor verification. Inspect the carburetor sockets for damage abnormalities, cracks, wear condition and unserviceabilities.Take note of temperature influence. Remove all spark plugs. Check caloric value and clean the spark plugs. Check electrode gap and adjust as necessary. Renew as required. Renew spark plugs. ATTENTION: Apply heat conduction compound on spark plug thread. 42. 43. Check spark plug connectors for security. Minimum pull-off force is 30 N (7 lb). Check compression by differential pressure method. X X X X X X X X X
EVERY 50 h
X X
100 h
X X
200 h
1 year
30. 31.
32. 33. 34. 35.
X X X X
36. 37. 38.
X X X
39. 40. 41.
X X X
X X
Page 5.16
July 17, 2007 - Rev. 11
MM - 200-25

SECTION: 5
FIRST POWER PLANT ITEM 25 h

Check the exhaust system for corrosion, burns, cracks, leaks and security. Remove the exhaust tube thermal insulator and inspect it for cracks, leaks and distortion. Repair or replace it, as necessary. Make sure that the exhaust system is at the correct distance from the engine mount or lower cowling. Clean the engine. Do not use easily imflammable engine, caustic cleaning agents or a high pressure cleaner. Refer to the Rotax Maintenance Manual for more instructions. X X
EVERY 50 h
X
100 h
X
200 h
1 year
X X
44. 45.
46. 47.
X X
Page 5.17
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST ENGINE TEST RUN ITEM

01. 02. 03. 04. Start the engine and run to operating temperature. Check ignition circuits at 4000 rpm engine speed. Check carburetor preheating. After engine test run, re-tighten the oil filter by hand.
EVERY 50 h
X X X X
25 h
X X X X
100 h
X X X X
200 h
1 year
Page 5.18
August 10, 2004 - Rev. 8
MM - 200-25

SECTION: 5
FIRST LEVELING AND WEIGHING ITEM

1. Perform weight and balance procedure at the end of the inspection, if necessary. NOTE: If aircraft basic weight is changed due to repair or paint, perform weight and balance procedure after the inspection.
EVERY 50 h 100 h 200 h 1 year

X
25 h
Page 5.19
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 5
FIRST GENERAL ITEM

01. 02. 03. 04. 05. Make sure that the airplane is clean. Check the aircraft is in accordance with Federal Regulation Authority specifications. Check that all applicable Service Bulletins and Airworthiness Directives have been properly applied. Check that Flight Manual is on board. Check that aircraft papers are updated and log books (airframe, propeller and engine) are correctly completed.
EVERY 50 h
X X X X X
25 h
100 h
X X X X X
200 h
1 year
X X X X X
Page 5.20
August 10, 2004 - Rev. 8
MM - 200-25

3. Recommended Lubricants Only use the lubricants and fluids approved. In case you use non-approved lubricants, the manufacturer is not responsible for the consequences. 3.1 Main Gear Calibrate the oleo-pneumatic shock struts to 130 psi (9.14 kg/ cm2) at ambient temperatures above 32F or 145 psi (10.19 kg/ cm2) at temperatures below 32F. Fill the shock strut with AEROSHELL FLUID 41 or Shell Tellus T37. 3.2 Brakes Use brake fluid AEROSHELL FLUID 41 or ESSO HD 400. The reservoir is in the engine compartment on the upper left side of the firewall. Examine minimum oil level. 3.3 Engine Oil Do not use aviation oils or additives. Only use motor oils with API classification "SG" or higher. For more information, refer to Rotax Service Instruction SI-912-016 / SI-914-019.
SECTION: 5
Page 5.21
MM - 200-25
July 17, 2007 - Rev. 11

SECTION: 5
CLIMATIC CONDITIONS
MULTI-GRADE OILS
40
100
TROPICAL
80
SAE 20W-50 SAE 20W-40
30
SAE 15W-50 SAE 15W-40
60 10
TEMPERATE
0
40
20
-10
0
ARCTIC
-20
-30
-20
Lubrication chart ATTENTION: THE AMBIENT GROUND AIR TEMPERATURES LISTED IN THE CHART ABOVE ARE MEANT ONLY AS A GUIDE SPECIFIED BY THE ENGINE MANUFACTURER AND AN INDICATION THAT A HIGHER VISCOSITY OIL SHOULD BE CONSIDERED WHEN THE OIL INLET TEMPERATURE APPROACHES THE MAXIMUM DURING OPERATION. 3.4 Engine Coolant Conventional coolant with 50% water content. See recomended coolant with a mixture of 50% antifreeze and 50 water in ROTAX SI-912-016 / SI-914-019.
Page 5.22
July 17, 2007 - Rev. 11
MM - 200-25
SAE 10W-40
20
SAE 5W-50 SAE 5W-40

4. Recommended Calibration Pressure 4.1 Main Gear Tires
SECTION: 5
Recommended pressure : 45 1.5 psi (3.2 0.1 Kg/ cm2)) 4.2 Tail Gear Tire
Recommended pressure : 36.2 1,5 psi (2.5 0,1kg/cm2) 5. Battery The battery GILL G-35 has the following characteristics : 12 V / 35 AH In case you need to recharge the battery, clean the terminals first. Do not let the current or the voltage reach more than 1,4 A and 12 V, respectively. Examine electrolyte level frequently. Maintain the level between 0.15 in and 0.30 in above the positive and negative plates. If the level is low, fill it with destilled water. In case of electrical system malfunction, refer to the electrical system diagram on Section 1. 6. General Maintenance 6.1 Fatigue
Fatigue mainly happens on rods, levers, mounts, mufflers, brackets and exhaust tubes because of high rates of vibration or high loads. Examine these parts carefully, specially their openings, angles, welding points and joints. You can identify fatigue by means of visible cracks but you can also use magnifying glass, penetrant or magnaflux. If you find a crack on a part not so important, drill a stop hole of 0.06 or 0.09 inches (2 or 3 mm) of diameter. If you find a crack on an important part, remove the part and replace it. 6.2 Erosion, Scratches and Nicks Erosion starts on wing leading edges and propeller blades. For propeller blades, refer to the Propeller Manual. For wings and composite material parts, refer to Section 4.
Page 5.23
MM - 200-25
August 10, 2004 - Rev. 8

6.3 Corrosion
SECTION: 5
In case you find signs of corrosion, follow procedures from Section 4. 6.4 Deterioration
Replace rubber and plastic components when superficial cracks start. 6.5 Composite Material Surface Damage
Only repair superficial damage (nicks, scratches, etc.). For larger repairs, contact the manufacturer or an authorized workshop to repair the damaged areas. 6.6 Anemometric System Obstruction
Check and clean dirty or clogged filter and anemometric hose . Replace filters, as necessary. In case of water condensing, disconnect instrument hose and use suction to the other end of the hose. 6.7 External Composite Material Surface Cleaning
Clean composite material surfaces with water and a foam or chamois leather. Make sure water does not penetrate the anemometric hoses. Never use silicone products to polish the surfaces. Never use gasoline, alcohol or solvents, etc. Protect the aircraft from humidity and heat for extended periods of time. Repair small cracks according to section 4. 6.8 Torques
Apply the recommended torques on bolts and nuts as specified on items shown in AMT-200S Parts Catalog. 7. Motorglider Service Life The motorglider service life corresponds to 3,000 flight hours. The service life can be progressevely extended to 4,000, 5,000 and 6,000 flight hours if the scheduled inspections described on BS100-10-021 are performed at authorized workshops. In case you need to extend service life even more, previous authorization must be obtained from the aeronautical certification authority.
Page 5.24
August 10, 2004 - Rev. 8
MM - 200-25

SECTION 6 - GENERAL 1. Special Tools Each aircraft is delivered with a special screw driver for the cowling d-zus and a special tool for removing and installing the horizontal stabilizer bolt. 2. Leveling the Motorglider The reference to level the aircraft is obtained with a 19.68 x 0.96 in (500 x 24,5 mm) block or wedge, supported on the extreme rear side of the canopy rail.
SECTION: 6
WEDGE
19.68 inches (500 mm) 0.96 inches (24.5 mm)
3. Ground Handling 3.1 3.2 3.3 Release parking brake. Fold the wings, if necessary. Put the cushions between the folded wings.
Page 6.1
MM - 200-25
August 10, 2004 - Rev. 8

SECTION: 6
4. Jacking CAUTION BEFORE YOU PUT THE AIRCRAFT ON JACKS, TIE ONE COUNTERWEIGHT TO THE TAIL TO PREVENT THE AIRCRAFT FROM OVERTURNING. Use the jack points located on the lower wing surface near the landing gear to put the aircraft on jacks. 5. Technical Documentation The following manuals are delivered with each aircraft: Flight Manual - P/N 200-24 Maintenance Manual - P/N 200-25 Parts Catalog - P/N 200-26 Operator's Manual for all versions of Rotax 912 - P/N 899.371 Maintenance Manual for Rotax Engine Type 912 Serie - P/N 899.372 Owner's Manual for Hoffmann Propeller HO-V62R-1/170 FA - P/N E 0107.72
Page 6.2
July 17, 2007 - Rev. 11
MM - 200-25

AMT-200S Maint Manual

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AMT 200S

MAINTENANCE MANUAL AMT 200S

August 10, 2004 - Rev. 8

MAINTENANCE MANUAL AMT 200S

Note: Do not use general aviation engine oil (detergent or not)

MAINTENANCE MANUAL AMT 200S

August 10, 2004 - Rev. 8

MAINTENANCE MANUAL AMT 200S

MAINTENANCE MANUAL AMT 200S

August 10, 2004 - Rev. 8

MAINTENANCE MANUAL AMT 200S

PP2A4N PP3B10N AIRCRAFT END BUS BAR GROUND

30A MAIN BUS BAR

MAIN/SOARING PP1C10 MASTER SOARING K2 SOARING PP5A10

SOARING BUS BAR

ENGINE RELAY BLACK RED 2A 2A

1 CHT 8 PP17A22 4 PP18A22 5

K1 MAIN PP1D10 PP1B10 PP4A10 30A MAIN

SHUNT HOUR METER

PRESSURE SWITCH E6A22

BUS BAR GROUND

+ E8A22 PP1C10 K2 SOARING

MAIN BUS BAR

MAIN/SOARING MASTER SOARING

20A PP5A10 SOARING HOUR METER SOARING BUS BAR

MAINTENANCE MANUAL AMT 200S

BUS BAR GROUND

SHUNT PP14A16 MASTER SWITCH PP6A20

OIL PRESSURE SWITCH E6A22

ON BATTERY CHARGER PLUG OFF

MAIN BUS BAR

STARTER RELAY PP1A4 BLACK RED

BUS BAR GROUND

K1 MAIN PP1D10 PP1B10 PP4A10 30A MAIN BUS FUSE LINE 2A

SHUNT PP14A16 MASTER SWITCH PP6A20

OIL PRESSURE SWITCH E6A22

ON BATTERY CHARGER PLUG OFF

MAIN BUS BAR E9A22 2A

July 17, 2007 - Rev. 11

MAINTENANCE MANUAL AMT 200S

KK3 A20 STARTER

5A MAI N BUS BAR STARTER

JK1A1 8 IGNIT ION A

JK2A18 IGNIT ION B JK4A 18 MAGNET O B

STARTER AND MAGNETO DIAGRAM

B C PP11A20 R 25V 22.000 uf E7A22 ALTERNATOR

MAIN BUS BAR

MAINTENANCE MANUAL AMT 200S

30A ALTERNATOR MAIN BUS BAR

F2A22 TURN BANK

F11A22 TURN BANK

2A F12A22N COPILOT MAIN BUS BAR F4A22 F3A22 GD

DIREC. GYRO F6A22N PILOT

F13A22 DIREC. GYRO F15A22N COPILOT

F8A22 ATT INDICATOR F8A22N PILOT

F17A22 ATT INDICATOR F18A22N COPILOT

FLIGHT INSTRUMENT DIAGRAM

July 17, 2007 - Rev. 11

MAINTENANCE MANUAL AMT 200S

F2A22 TURN BANK (OPTIONAL) F3A22N PILOT

F11A22 TURN BANK (OPTIONAL) F12A22N COPILOT

DIREC. GYRO (OPTIONAL) F6A22N PILOT

F13A22 DIREC GYRO (OPTIONAL) . F15A22N COPILOT