amt-200s maint manual
TRANSCRIPT
200-25
MAINTENANCEMANUAL
AMT 200S
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
SECTION 1 - DESCRIPTIONS, SYSTEMS, RIGGINGS AND PLACARDS
1. Motorglider Characteristics
1.1 Basic Dimensions
Wing span 57.32 ft (17.47 m)
Wing span with winglets (optional) 57.97 ft (17.67 m)
Wing span (wings folded) 33.30 ft (10.15 m)
Length 26.50 ft (8.08 m)
Maximum height 6.33 ft (1.93 m)
1.2 Wings
Wing surface (area) 201.29 Sqft (18.70 m2)
Dihedral 2° 30'
Profile Naca 643618
Angle of incidence 2°
Wing torsion -2°
1.3 Ailerons
Percent to wing chord (depth) 30%
Aileron span 10.24 ft (3.12 m)
Aileron surface (area) 7.32 Sqft (0.68 m2)
1.4 Airbrakes
Position at 45% of wing chord
Airbrake span 4.76 ft (1.45 m)
Type Schempp hirth on upper wing
surface
1.5 Horizontal Stabilizer
Horiz. stabilizer span 12.07 ft (3.68 m)
Horiz. stabilizer surface (area) 31.21 Sqft (2.90 m2)
Elevator surface 10.23 Sqft (0.95 m2)
Horiz. stabilizer - angle of incidence -1°
Page 1.1
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
1.6 Vertical Empennage
Vertical empennage surface (area) 22.93 Sqft (2.13m2)
Rudder surface (area) 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) >0°CPressure 145 psi (10,19 kg/cm2) <0°C
Main wheel tire: 330 x 130 (5.00-4) pressure 45 psi (3.2 kg/cm2)
Tail wheel tire: 210 x 65 CR17 pressure 36.2 psi (2.5 kg/cm2)
Main landing gear track: 9.18 ft (2.80 m)
Distance between front and rear landing gear axes: 16.51 ft (5.35 m)
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
MAINTENANCE MANUAL
AMT 200S SECTION:1
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
- 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
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
1.12 Air Pressure Ports
1. Dynamic air pressure port
2. Static air pressure port
3. Total energy
Page 1.4
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.5
August 10, 2004 - Rev. 8
1.13 Vent holes and drains
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
2. Electrical Diagram
Page 1.6
August 10, 2004 - Rev. 8
BATTERY DIAGRAM(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)
BATTERY DIAGRAM(Motorgliders s/n 200.128 to 200.132)
MAIN
SOARINGPP5A10
PP4A10
PP1B10
BLACK
RED
BUS BARGROUND
MAIN/SOARING
PP8A20N
PP1C10
PP7A20
SOARINGK2
PP6A20
MASTER
ENGINE GROUND
PP3A4N
AIRCRAFT END
PP3B10N
PP2A4N
PP1D10
K1
SHUNT
PP1A4
ENGINE RELAY
20ASOARING BUS
BAR
PP18A22
PP17A22
2A
2A
30A
CHT
11
MAIN BUSBAR
AM
ME
TE
R/C
HT
55
88
44
BATTERY
PP5A10
MAIN/SOARING
PP8A20N
AIRCRAFTGROUNDBUS BAR
ENGINE
PP2A4N
PP3A4N PP1D10
PP7A20
MASTER
PP6A20
SOARING
PP1C10
SHUNT
PP1B10
K2
SOARING
MAIN
PP1A4
2A
ENGINE RELAY
BLACK
RED PP18A22
PP17A22
CHT
SOARING
20A
PP4A10
MAIN
30A
AMMETER/CHT
44
88
55
11
+
-
HOUR METER
2A
FUSE
LINE
MAIN BUS
BAR
E9A22
E10A22
+-
HOUR METER
2A
SPARE
BUS BAR
SOARING
SWITCHPRESSURE
E8A22
E7A22 E6A22
BATTERY
SHUNT
K1
2A
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.7
July 17, 2007 - Rev. 11
BATTERY DIAGRAM(Motorglider s/n 200.133 and on)
BATTERY DIAGRAMOptional Configuration
FIREWALL
GROUNDBUS BAR
PP2A4N
PP15A16N
BATTERY CHARGER PLUG
PP3A4N
STARTER RELAY PP1A4
PP1A4TO STARTER RELAY
PP1D10
PP6A20PP8A20N
PP14A16
ON
OFF
MASTERSWITCH
PP1C10
PP1B10
K2
MAIN
2ABLACK
RED PP18A22
PP17A22
CHT
PP4A10
MAINBUS
30A
AMMETER/CHT
4
8
5
1
+
-
HOUR METER
2A
FUSELINE
MAIN BUS
BAR
SWITCHOIL PRESSURE
E8A22
E7A22 E6A22
BATTERY
SHUNT
K1
2A
E9A22
E10A22
+-
HOUR METER
2A
10A
FIREWALL
GROUNDBUS BAR
PP2A4N
PP15A16N
BATTERY CHARGER PLUG
PP3A4N
STARTER RELAY PP1A4
PP1A4TO STARTER RELAY
PP1D10
PP6A20PP8A20N
PP14A16
ON
OFF
MASTERSWITCH
PP1C10
PP1B10
K2
MAIN
2ABLACK
RED
PP4A10
MAINBUS
30A
+
-
HOUR METER
2A
FUSELINE
MAIN BUS
BAR
SWITCHOIL PRESSURE
E8A22
E7A22 E6A22
BATTERY
SHUNT
K1
2A
E9A22
E10A22
+-
HOUR METER
2A
10A
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.8
July 17, 2007 - Rev. 11
ALTERNATOR DIAGRAM(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)
G
G
B
C
R
25V22.000 uf
ALTERNATOR
E7A22
KK3A20 30A
ALTERNATOR
HOUR METER
MAINBUSBAR
PP11A20
K4
MAGNETO B
MAGNETO A
KK3A20
JK4A18
JK3A18
PP1A4
BATTERY
KK1A4
K3
IGNITION B
IGNITION A
JK2A18
JK1A18
KK5A22
KK2A20
STARTER STARTER
5A
M
STARTER
MAIN BUS BAR
LANDING GEAR
ALARM
KK6A20N
STARTER AND MAGNETO DIAGRAM(Motorgliders s/n 200.119, 200.122 and on)
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.9
July 17, 2007 - Rev. 11
PP12A20N
G
G
B
CC
RVOLTAGE REGULADOR
FUSE LINE
PP13A20
22.000 uf
25V
PP10A10
PP11A20
ALTERNATOR
K4
PP9A1030A
ALTERNATOR
MAIN BUS
BAR
5A
22.000 uf
K4
ALTERNATOR
ALTERNATOR DIAGRAM(Motorglider s/n 200.128 and on)
FLIGHT INSTRUMENT DIAGRAM(Motorgliders s/n 200.119, 200.122 to 200.132)
F7A22
F14A22
F1A22
DIREC.
GYRO
F8A22
ATT
INDICATOR
F13A22
F2A22
TURN BANK
2A
ATT
SOARING BUS
2A
GD
T&B
2A
MAIN BUS BAR
F3A22N
PILOT
F12A22N
COPILOT
TURN BANK
F11A22 F10A22
2A
T&B
GYRO
DIREC.F4A22 F3A22
2A
GD
F6A22N
PILOT
F15A22N
COPILOT
F8A22N
PILOT
F18A22N
COPILOT
INDICATOR
ATT
F17A22 F16A22
2A
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.10
July 17, 2007 - Rev. 11
F7A22
F14A22
F1A22
DIREC
.GYRO
(OPTIONAL)
F8A22
ATTINDICATOR(OPTIONAL)
F13A22
F2A22
TURN BANK(OPTIONAL)
2A
ATT
2A
GD
T&B
2A
MAIN BUS BAR
F3A22N
PILOT
F12A22N
COPILOT
TURN BANK(OPTIONAL)
F11A22 F10A22
2A
T&B
DIREC.GYRO
(OPTIONAL)
F4A22 F3A22
2A
GD
F6A22N
PILOT
F15A22N
COPILOT
F8A22N
PILOT
F18A22N
COPILOT
ATTINDICATOR(OPTIONAL)
F17A22 F16A22
2A
FLIGHT INSTRUMENT DIAGRAM(Motorgliders s/n 200.133 and on)
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
WARNING SYSTEM DIAGRAM
(LANDING GEAR, AIRBRAKE, STARTER ENGAGED, LOW BATTERY)
(Motorgliders s/n 200.119, 200.122 to 200.132)
4
5
6GW3A22
6
4
5
33
22
11GW3C22
GW2D22N
GW5B22
NO
C
NC
LEFT GEAR
MICRO SWITCH CONNECTOR
LEFT WING
MICRO SWITCH
RIGHT GEAR
NC
C
NO
GW5C22
GW2E22N
GW1C22
33
22
11
CONNECTOR
6
4
5
RIGHT WING
GW1A22
AIR BRAKE
MICRO SWITCH
NC
C
NO
GW6A22
GW2B22N
GW2A22N
GW2C22N
MICRO SWITCH
NC
NO
C
GW5A22
GW4A22
GEAR UP
GW5D22
GW12A22
GW1B22
GEAR LIGHT
2A
GW1B22
GW3B22
SOARING
BUS
GW4B22
RIGHT GEAR LEFT GEAR
DOWN DOWN35
4
1GW10A22GW11A22N
TEST
RETRACTED OR
IN TRANSIT
10
12
PW2A22
KK4A22
12
13
PW3A22N
KK5A22STARTER
STARTER
ENGAGED
LOW
BATTERY
2
CANCEL
GW9A22
GW7B22
BUS
SOARING
2A
GEAR WARN
LOW BATT
2A
GW7C22
PW4A22N
GW7A22
PW1A22
3
9
11
Page 1.11
July 17, 2007 - Rev. 11
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.12
July 17, 2007 - Rev. 11
WARNING SYSTEM DIAGRAM
(LANDING GEAR, AIRBRAKE, STARTER ENGAGED, LOW BATTERY, COOLANT LEVEL)
(Motorgliders s/n 200.133 and on)
GEAR LIGHT
4
5
6GW3A22
6
4
5
3
2
1GW3C22
GW2D22N
GW5B22
NO
C
NC
LEFT GEAR
MICRO SWITCH CONNECTOR
LEFT WING
MICRO SWITCH
RIGHT GEAR
NC
C
NO
GW5C22
GW2E22N
GW1C22
3
2
1
CONNECTOR
6
4
5
RIGHT WING
GW1A22
AIR BRAKE
MICRO SWITCH
NC
C
NO
GW6A22
GW2B22N
GW2A22N
GW2C22N
MICRO SWITCH
NC
NO
C
GW5A22
GW4A22
GEAR UP
GW5D22
GW12A22
GW1B22
GEAR LIGHT
2A
GW1B22
GW3B22
GW4B22
RIGHT GEAR LEFT GEAR
DOWN DOWN35
4
1GW10A22GW11A22N
TEST
RETRACTED OR
IN TRANSIT
10
12
PW2A22
KK4A22
12
13
PW3A22N
KK5A22STARTER
STARTER
ENGAGED
LOW
BATTERY
2
CANCEL
GW9A22
GW7B22
GW7C22
PW4A22N
GW17A22
GW7C22
GN16A22
GW
13
A22
GW
15
A22
GW18A22NSENSOR
COOLANT LEVEL
LOW BATT
GEAR WARN
GW7A22
PW1A22
3
9
2A
2A
2A
11
15
7
8
14
M
AIN BUS
WAR
NING SYS
TEM UNIT
WAR
NING SYST
EM UNIT
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.13
July 17, 2007 - Rev. 11
OIL TEMPERATURE / PRESSURE DIAGRAM - Standard configuration
4
5
3
1 OIL TEMP. SENDER
OIL PRESSURE SENDEROIL TEMP./
PRESSURE
INDICATOR
GNDBATTERY
MAINBUS
E8A22N
E2A22
E3A22
E1A22
E4A22N
2A
5ARV1A18RV1A18
2AF5A22
2AF3A22
2AF1A22
3ASN1A20
2A
ALTITUDE ENCODER
TRANSPONDER
VHF/COMM
ATT INDICATOR (OPTIONAL)
INTERCOM (OPTIONAL)
TURN AND BANK (OPTIONAL)
VHF/COMMB
ARVZA18N
TRANSPONDERB
ASN2A20N
ALTITUDEENCODER
B
ABLACK
JN3A22
AVIONICS DIAGRAM - Standard configuration
OIL TEMPERATURE / PRESSURE AND RPM INDICATION
Optional Configuration
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.14
July 17, 2007 - Rev. 11
Q5A22
D 15B
D 15B
Q4C22
Q4E22
Q5B22
Q6B22
Q7E22N
Q7E22N
Q4A22
Q7B22N
Q7A22N
Q6A22
FUEL
LEVEL
INDICATOR
2A
FUEL INDICATOR
3
5
1
1
2
3
1
2
3
RED
YELLOW
BLACK
RED
YELLOW
BLACKSENDER
RIGHT
SENDER
LEFT
1
2
3
1
2
3
5A
PM2B20PM2B20N
PM1A20PM2A20NAUX. POWER
LEFT AUX. POWER
RIGHT AUX. POWER
5AQ1A18Q2A18Q3A18N
FUEL PUMPFUEL PUMP
AVIONICS DIAGRAM - Standard configuration
FUEL LEVEL DIAGRAM - Standard configuration
FUEL LEVEL DIAGRAM
Optional Configuration
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.15
July 17, 2007 - Rev. 11
44
55
4
4
4
1
2
6
3
4
2
6
25
4
5
4
4
3. Ground Connecting Straps
Ground Connecting Straps Table
STRAP
1
2
3
4
5
6
IPC REFERENCE
IPC FIGURE 05
IPC FIGURE 13
IPC FIGURE 15
IPC FIGURE 16
IPC FIGURE 18
IPC FIGURE 20
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
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
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.
Find the fuel system components below.
1- Tank cap and vent (breather)
2- Drain valves
3- Left fuel tank 11.89 U.S gallons (45 liters)
4- Right fuel tank11.89 U.S gallons (45 liters)
5- Fuel tubes and connections
6- Electric fuel pump
7- Carburetor
8- Mechanic fuel pump
9- Fuel filter
10- Three position fuel selector valve
Page 1.16
August 10, 2004 - Rev. 8
TOTAL
11.89 US gallons (45 litres)
11.89 US gallons (45 litres)
23.78 US gallons (90 litres)
USABLE
11.62 US gallons (44 litres)
11.62 US gallons (44 litres)
23.24 US gallons (88 litres)
Left Wing Tank
Right Wing Tank
Total Capacity
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Fuel System
Page 1.17
August 10, 2004 - Rev. 8
CARBURETORVENT AND
DRAIN TUBE
FIREWALL
FUEL RETURNING LINETO FUEL TANKS
3
2 2
4
6
10
98
7
5
7
5
5
5
5
5
5
5
5
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
5. Brake System
5.1 Find below the basic components of the brake system.
1- Fluid reservoir
2- Master cylinders
3- Tubes
4- Fittings
5- Flexible tubes
6- Brake cylinder
7- Bleeder valve
5.2 Only use approved brake fluids: Aeroshell Fluid 41 or Esso HD 400.
5.3 Measure brake lining thickness (minimum 0.100 inches).
5.4 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
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Brake System
Page 1.19
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
6. Aileron Controls
6.1 Find below basic components of the Aileron Control System
1- Control Stick
2- Aileron rod n° 1
3- Aileron rod n° 2
4- Aileron rod n° 3
5- Aileron rod n° 4
6- Aileron link rod
7- Inboard and outboard ailerons
8- Bellcrank n° 1
9- Bellcrank n° 2
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 27112-
IPC fig. 13 D item 60) to 1 (one) degree downward on the two ailerons.
Page 1.20
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
6.2.5 Record the neutral position in a table as the example below
6.2.6 Release the control stick by removing tool P/N 27100 D/E-A-28 F1.
6.2.7 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.
Neutral
Up
Down
AILERON (RH)
ß(+ 1°)
AILERON (LH)
0° ± 1°
15° ± 1°
15° ± 1°
Neutral
Up
Down
AILERON (RH)
0° ± 1°
15° ± 1°
15° ± 1°
Page 1.21
August 10, 2004 - Rev. 8
AILERON (LH)
α(+ 1°)
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.22
August 10, 2004 - Rev. 8
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 up-
stop 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
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Aileron Controls
Page 1.23
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
7. Elevator Control System
7.1 Find below basic components of elevator control system.
1- Control stick
2- Rod n° 1
3- Rod n° 2
4- Rod n° 3
5- Rod n° 4
6- Bellcrank n° 1
7- Bellcrank n° 2
8- Bellcrank n° 3
9- Bellcrank n° 4
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 TH-5x25-RT and TH-5x40-RT referenced above. See elevator control surface travel onsection 3.
Page 1.24
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Elevator Control
Page 1.25
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
8. Rudder Control System
8.1 Find below the basic components of the Rudder Control System
1- Rudder pedals
2- Control cables
3- Rudder bellcrank
4- Rudder
8.2 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
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Rudder Control
Page 1.27
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
9 Elevator Trim Control System
9.1 Basic components of the Trim Control System:
1- Trim control wheel assembly
2- Trim tab wheel indicator
3- Cartridge spring
4- Elevator control rod
5- Cable assembly support
6- Cable
9.2 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
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Trim Control System
Page 1.29
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
10. Airbrake Control System
10.1 Basic components
1- Airbrake control lever
2- Airbrake control link rod
3- Airbrake angular transmission gear box
4- Airbrake push rod
5- Airbrake torque tube (rod)
6- Airbrake housing
10.2 Rigging
(1) Extended: Inspect the correct airbrake extension by adjusting the stop screw
at the base of the control lever below the center console.
(2) Retracted: 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)
1- Keep airbrakes retracted and locked.
2- Approach the micro switch to the airbrake control lever until activate micro
switch is depressed.
3- Tighten the micro switch in this position.
Page 1.30
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Airbrake Control System
Figure 2
Page 1.31
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Figure 3
1- Airbrake control lever
2- Center console
3- Airbrake control link rod
4- Stop screw
5- Airbrake micro switch
Page 1.32
August 10, 2004 - Rev. 8
Figure 2
6.38 ± 0.31 in
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
This page intentionally left blank
Page 1.33
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
11. Main Landing Gear Control System
11.1 Basic components
1- Landing gear control lever
2- Landing gear control rod
3- Landing gear torque tube
4- Landing gear gear box
5- Link rod
6- Control arm
7- Rod
8- Landing gear assy
Page 1.34
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Main Landing Gear Control System
Page 1.35
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
11.2 Main Landing Gear Rigging
11.2.1 Put the aircraft on jacks
11.2.2 Landing Gear Up-Lock Rigging (See Figure below)
(a) Retract the landing gear
(b) Adjust the length of the link rod (1) on the rod ends until you obtain an effective
landing gear uplock
(c) Extend and retract the landing gear several times.
Note:
Do the procedure above for the two main gears.
1- Link rod 5- Control Arm
2- Compensation Spring 6- Stop screw
3- Rod 7- Landing gear leg (fixed strut)
4- Crank 8- Wing spar
Page 1.36
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
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.
Detail A
1- Link rod 6- Stop screw
2- Compensation Spring 7- Landing gear leg (fixed strut)
3- Control Arm 8- Wing spar
4- Gearbox control lever 9- Landing gear fork
5- Rod 10- Locking mechanism
11- Micro switch
Page 1.37
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
11.4 Landing Gear Control Lever Rigging - (See figure below)
11.4.1 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.
(2) Tighten the nut of the control link rod and lock it using a lock washer.
1- Landing gear control lever
2- Landing gear control link rod
3- Landing gear torque tube
4- Retracted landing gear micro switch
5- Center console
Page 1.38
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
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
(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:
11.6.1.1 ln the up position make sure that the individual gear is positively
locked by pulling the gear down.
11.6.1.2 The control lever must have some resistance after unlocking
from the up position.
Page 1.39
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
11.6.1.3 The lever must show positive sign of locking in the down position
(backwards).
11.6.1.4 Make sure that each upper articulated strut does not let the landing gears
retract
11.6.1.5 Make sure that all rod lock nuts are tightened and locked.
11.6.2 The warning must sound in the following situations:
11.6.2.1 Landing gear in transit and airbrakes extended or retracted. Landing gear up
and airbrakes extended.
CAUTION:
Inspect the operation of the warning silencing switch with the airbrakes extended and the landing
gear up or in transit.
11.6.2.2 Inspect all safety pins or wires of the rods; (eliminate all or eventual interferences
which permit the lock nuts and threaded parts to unscrew).
11.6.2.3 Inspect the correct attachment of the micro switches.
11.7 Main Landing Gear - Movable Strut Removal
11.7.1 Put the aircraf on jacks, without touching the ground, and use a toil weight
to avoid aircraft forward drop from jacks.
11.7.2 Release the gas pressure from the shock absorbe.
11.7.3 Remove the brake cylinder assembly.
11.7.4 Remove the landing gear lower cover.
11.7.5 Keep the wheel supported by a block.
11.7.6 Release the torque links by removing its screw.
11.7.7 Remove the plate (flange) by releasing the screws.
11.7.8 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
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
Page 1.41
November 23, 2004 - Rev. 9
ln order to identify the main subassemblies of the motorglider AMT-200S Super Ximango, refer to
the table below:
MAINTENANCE MANUAL
AMT 200S SECTION:1
MM - 200-25
This page intentionally left blank
Page 1.42
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 1
MM - 200-25
13. Placards
Standard version
Optional - Factory Incorporated Only
29
35
1727 4
2
163436
2816 3
25
19
18
24 5
32
30
31
133
6
7
10
9
8
23
11
2121
22
29
35
1727 4
2
163436
2816 3
25-B
19
5-A
21-A
23
22
18
24
32
30-B
31
1
33
6
7
10
9
8
11
47
Page 1.43
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 1
MM - 200-25
Optional - Factory Incorporated Only
29
35
174
2
3634
44
463
25C
19
27
32
43
44
45
18
21A
24
23
31
30
5
22
133
6
7
10
9
8
11
Optional - Factory Incorporated Only
29
35
174
2
3634
44
47
46
3
25D
19
27
32-B
43
44
45-B
18
21-A
24
23
31
30-B
5-A
22
133
6
7
10
9
8
11
48
Page 1.44
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 1
MM - 200-25
Optional - Factory Incorporated Only
Optional - Factory Incorporated Only
343
19
27
31
30-B22
32-E
25-G
3824
29
35
174
2
3618
133
6
7
10
9
8
11
21-A
21-A
2323
5-A
5-A
343
19
27
31
30-B22
32-C
25-E
24
29
35
174
2
3618
133
6
7
10
9
8
11
21-A
21-A
2323
5-A
5-A
Page 1.45
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 1
MM - 200-25
Optional - Factory Incorporated Only
34348-A
44-A 44-A
43-A
25G
19
27
32-E
5-A
24
23
31
30-B
21-A22
29
35
174
2
3618
133
6
7
10
9
8
11
AIRFRAME TIME
ENGINE TIME
Optional - Factory Incorporated Only
29
35
174
2
3618
133
6
7
10
9
8
11
3
372 4
A
48-A
4
47
4-A44-
43-A
25H
19
32-E
5-A
24
23
31
30-B
21-A22
Page 1.46
October 10, 2005 - Rev. 10
MAINTENANCE MANUAL
AMT 200S SECTION: 1
MM - 200-25
Page 1.47
October 10, 2005 - Rev. 10
3 43
49
50
51
49
39 39
37 37
44-A 44-A
43-A
2 7
2 9
35
1 7
4
2
3 61 8
13 3
6
7
1
1
0
1
9
8
21-A
21-A
2323
5-A
5-A
19
3 1
3 0 -B
2 2
3 2 -G
2 5 -J
2 4
Optional - Factory Incorporated Only
343 27
29
35
174
2
3618
133
6
7
10
9
8
11
21-A
21-A
2323
5-A
5-A
19
31
30-B22
32-F
25-I
3824
Optional - Factory Incorporated Only
MAINTENANCE MANUAL
AMT 200S SECTION: 1
MM - 200-25
Page 1.48
July 17, 2007 - Rev. 11
Optional - Factory Incorporated Only
3 4
3
27
2 9
35
1 7
4
2
3 61 8
13 3
6
7
1
1
0
1
9
8
19
22
32-H
25-K
30-B
38
2 4
21-A
23
5-A
Optional - Factory Incorporated Only
29
35
17
4
2
18
1 33
6
7
10
11
9
8
24
25-L
30-C
22
3
43-A
44-A48-D
44-A
34
32-I27
3136
21-A
23
5-A21-A
23
5-A
MAINTENANCE MANUAL
AMT 200S SECTION: 5
MM - 200-25
Página 5.1
Agosto 10, 2004 - Rev. 8
SECTION 5 - MAINTENANCE CHECKS
1. External Visual Inspection
Inspect the aircraft before every flight to prevent failures or even accidents.
1.1External Inspection
(1) Cabin
- 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.
MAINTENANCE MANUAL
AMT 200S SECTION: 5
MM - 200-25
Página 5.2
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 ½ inches and
normal 2 ½ inches).
(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.
MAINTENANCE MANUAL
AMT 200S SECTION: 5
MM - 200-25
Página 5.3
July 17, 2007 - Rev. 11
- 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.
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
OPERATIONAL
INSPECTION
Page 5.4
August 10, 2004 - Rev. 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
NOTE: Before checking oil level, turn propeller over severaltimes to ensure that crankcase oil has been returned to theoil tank.This process finishes when air is returning back tothe oil tank and can be noticed by a murmur from the openoil tank.
Do engine run-up and record all engine parameters.
Check electric and engine-driven fuel pumps and fuel tankselector.
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 forfreedom of movement and correct deflection.
Check pedals for position detents and brake operation.
Check canopy locking mechanism from inside andoutside.
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 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
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
CONTROL CABIN
Page 5.5
August 10, 2004 - Rev. 8
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 valvecloses correctly.
Check pitot and static lines for security, condition andleaks.
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 correctattachment and condition (if applicable).
Check compass correction card.
Recalibrate the compass.
Inspect internal illumination and instrument panelillumination (if equipped).
Inspect navigation lights, anti-collision lights and landinglight (if installed).
Check fire extinguisher.
Check internal placards.
Check identification plate.
Check air brakes for RETRACTED, EXTENDED andintermediate positions. Make sure that the two air brakesmove symmetrically.
NOTE: If the air brakes do not move symmetrically, contactAEROMOT for more instructions.
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 X
X
X X X
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
CONTROL CABIN
Check cables and connections located under controlcolumn 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 .
X X X
X X X
X X X
X
16.
17.
18.
19.
Page 5.6
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
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
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. Lubricaterails.
Inspect external placards.
Check drain holes and static ports for obstruction.Clean holes and ports, if required.
Inspect optional equipment attaching points andsupports.
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
FUSELAGE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page 5.7
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
WINGS
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. Makesure it is clear.
Remove wing/ fuselage adhesive tape.
Make sure that flight control cables are clear in thewing folding area.
Inspect wing spar ends for damage.
Check wing folding mechanism for condition, corrosionand wear. Make sure it locks correctly. Lubricate, asnecessary.
Check surface drain holes for condition and obstructions.
Check ailerons for chafing, unusual noise, deformationand plays; check vent holes for condition andobstructions
Inspect aileron support and bellcranks for lubricationand condition.
Check aileron control rods for chafing, routing andtravel limits.
Check aileron attaching bearings for axial and radi-al plays. In case you find plays, repair as necessary.
Inspect wing/fuselage attachment for plays.
Inspect wing surface near the landing gear for deformationand corrosion.
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 X
X X X
X X X
X X X
X X X
X X X
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Page 5.8
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
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 surethat 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 fueltanks, if required.
Install new adhesive tape.
Install access panels.
X X X
X X X
X X X
X X X
X
X
X
X
X X X
X X X
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
WINGS
Page 5.9
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
STABILIZER (HORIZ. AND VERT.)
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 correcttorque of the attaching screw .
Lubricate elevator and rudder rod ends.
Check elevator control rod for chafing, routing andtravel.
Check elevator trim for chafing, freedom ofmovement and travel. Compare the positions of thesurface and the indicator.
Check vertical stabilizer supports and bearings forcorrosion.
Check rudder attach points; check rudder vent hole
Check rudder attaching nut for correct torque.
Use a 10x glass to inspect rudder axles and sphericalbearings 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 X
X
X X X
X X X
X X X
X X X
X X X
X X X
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X X
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01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12
13.
14.
15.
16.
Page 5.10
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
LANDING GEAR
Put aircraft on jacks.
Put an assistant in the control cabin. Ask this person toextend and retract the landing gear while you make surethat the wheels fit correctly into the wheel well. The coversmust also close correctly.
NOTE: If the landing gear legs do not retract symmetrically,there is a malfunction on the angular gear box and youmust contact AEROMOT for more instruction.
Remove the central console and make sure that thelanding gear control handle fits correctly in the EXTENDEDand RETRACTED positions.
Inspect landing gear uplock microswitch and air brakeswarning microswitch
Inspect downlock microswitch.
Check landing gear warning system.
Check shock struts for corrosion, correct travel andleakage.
CAUTION: In case of leakage, disassemble shock strutusing the tool P/N 35350-A-23 because of the compressedinternal spring and replace oil leaking o'rings.
Inspect landing gear legs, torque links, drag brace anddownlock for corrosion, cracks and proper attachment.
Calibrate shock struts, if required.
Inspect tires for wear, cuts, pressure leakage andslippage.
Remove the wheels and inspect the sealed bearings forwear.
CAUTION: Do not put and clean the sealed bearings intohydrocarbon solvents.
X X X
X X X
X X X
X X X
X X X
X X X
X X X
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X X X
X X
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
Page 5.11
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
LANDING GEAR
X X X
X X X
X X X
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X
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X X X
X X X
Inspect wheels for cracks using a 10x glass.
NOTE: In case of hard landing or 500 flight hours, inspectwheels with penetrant.
Inspect brake linings and discs for wear, distortion anddeformation.
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.
12.
13.
14.
15.
16.
16.
17.
18.
Page 5.12
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
PROPELLER
Remove spinner
Inspect spinner and plate for cracks, deformationand attaching hole wear.
Inspect propeller attaching nuts. Torque the nuts to390-410 in.lb. and apply the torque seal.
Use a magnifying glass to check propeller bladesfor vibration spots, wear and cracks. Repair thepropeller according to the Propeller Manual ( ifrequired).
Check for smooth turning of the blades.
Slightly grease the four pitch change rods of theoutside pitch change mechanism where they slide intothe 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 sealedwith silicone rubber material.
Check pitch change cable for condition.
Install spinner
NOTE: Overhaul the propeller every 1500 flight hours or 7years whichever comes first.
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
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
Page 5.13
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
POWER PLANT
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 thatbatterybox drain is clear.
Make sure that the cell filler caps close correctly.
Inspect the electrical box.
Check electrical wiring, fuses, relays and capacitor forwear and interference.
Inspect alternator connectors for security andcorrosion.
Check power plant cables for condition andsecurity.
Inspect starter for condition and corrosion.
Inspect the engine for damage and abnormalities.
Inspect cooling air ducts, baffling and cylinder cooling finsfor obstructions, cracks, wear and condition. Take note oftemperature influence.
Inspect temperatures and pressure sensors for securityand condition.
Inspect all coolant hoses for damage, leak, hardening fromheat, porosity, loose connections and secure attachments.Verify routing for kinks and restricted elbows.
Inspect the leakage bore at the base of the water pump forsigns of leakage.
X X X X
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X X X X
X X X X
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X X X X
X X X X
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
Page 5.14
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
POWER PLANT
Inspect the expansion tank fordamage and abnormalities. Verify coolant level, fill asnecessary. Check radiator cap. Inspect rubber plate onexpansion tank base for secure fit.
Inspect and clean the low level sensor of expansion tank
Inspect the overflow bottle for damage andabnormalities.Verify coolant level, replenish as necessary.Check line from expansion tank to overflow bottle fordamage, leakage and clear passage.Verify venting bore in cap of overflow bottle for clearpassage.
Inspect all oil hoses for damage, leak, hardening fromheat, 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, hardeningfrom 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 partsfor security and fit. Check safety wiring, renew asnecessary.
Check the backlash.
Check the friction torque. Record Actual Friction TorqueSee 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 oilfilter.Lubricate mating sealing ring of new oil filter withengine oil. Screw on new filter by hand.
Cut oil filter housing without producing any metal chipsand inspect filter mat.
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
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X X
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Page 5.15
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
POWER PLANT
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Renew gasket ring of drain screw on oil tank.Fit drainscrew 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 ServiceInformation ROTAX SI-912-016 / SI-914-019.
Flush the coolant system.
Inspect the air filter.
Do the carburetor synchronization check. Mechanical orpneumatic synchronization.
Checkthe float chamber venting. Check venting lines forcondition, secure attachment, clear passage and routingfor kinks and restrictions.
Check free movement of the carburetor activation (throttlelever and starting carb).
Remove and install the carburetors in the course ofcarburetor verification.
Inspect the carburetor sockets for damage abnormalities,cracks, wear condition and unserviceabilities.Take noteof temperature influence.
Remove all spark plugs. Check caloric value and clean thespark plugs.
Check electrode gap and adjust as necessary. Renew asrequired.
Renew spark plugs.
ATTENTION:
Apply heat conduction compound onspark plug thread.
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 X
X
X X
X X
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X
X
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X
X X X
X
Page 5.16
July 17, 2007 - Rev. 11
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
POWER PLANT
44.
45.
46.
47.
Check the exhaust system for corrosion, burns, cracks,leaks and security.
Remove the exhaust tube thermal insulator and inspect itfor cracks, leaks and distortion. Repair or replace it, asnecessary.
Make sure that the exhaust system is at the correctdistance from the engine mount or lower cowling.
Clean the engine. Do not use easily imflammable engine,caustic cleaning agents or a high pressure cleaner. Referto the Rotax Maintenance Manual for more instructions.
Page 5.17
August 10, 2004 - Rev. 8
X X X
X
X
X X X
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
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.
X X X
X X X
X X X
X X X
ENGINE TEST RUN
01.
02.
03.
04.
Page 5.18
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
LEVELING AND WEIGHING
1. Perform weight and balance procedure at the end ofthe inspection, if necessary.
NOTE: If aircraft basic weight is changed due to repairor paint, perform weight and balance procedure after theinspection.
X
Page 5.19
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
FIRST EVERY
ITEM 25 50 100 200 1
h h h h year
MM - 200-25
Make sure that the airplane is clean.
Check the aircraft is in accordance with FederalRegulation Authority specifications.
Check that all applicable Service Bulletins andAirworthiness Directives have been properly applied.
Check that Flight Manual is on board.
Check that aircraft papers are updated and logbooks (airframe, propeller and engine) are correctlycompleted.
X X X
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X X X
X X X
GENERAL
01.
02.
03.
04.
05.
Page 5.20
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
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 32ºF or 145 psi (10.19 kg/ cm2) at temperatures below 32ºF. 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.
Page 5.21
July 17, 2007 - Rev. 11
MAINTENANCE MANUAL
AMT 200S SECTION: 5
MM - 200-25
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
40
ºC ºF
30
20
10
0
-10
-20
-20-30
0
20
40
60
80
100
CLIMATICCONDITIONS
MULTI-GRADE OILS
TROPICAL
TEMPERATE
ARCTIC
SA
E 2
0W
-50
SA
E 2
0W
-40
SA
E 1
5W
-50
SA
E 1
5W
-40
SA
E 1
0W
-40
SA
E 5
W-5
0
SA
E 5
W-4
0
MAINTENANCE MANUAL
AMT 200S SECTION: 5
MM - 200-25
4. Recommended Calibration Pressure
4.1 Main Gear Tires
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
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 5
MM - 200-25
Page 5.24
August 10, 2004 - Rev. 8
6.3 Corrosion
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.
MAINTENANCE MANUAL
AMT 200S SECTION: 6
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.
WEDGE
19.68 inches (500 mm)
0.96 inches
(24.5 mm)
3. Ground Handling
3.1 Release parking brake.
3.2 Fold the wings, if necessary.
3.3 Put the cushions between the folded wings.
Page 6.1
August 10, 2004 - Rev. 8
MAINTENANCE MANUAL
AMT 200S SECTION: 6
MM - 200-25
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