amt-200s maint manual

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200-25 MAINTENANCE MANUAL AMT 200S

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Page 1: AMT-200S Maint Manual

200-25

MAINTENANCEMANUAL

AMT 200S

Page 2: AMT-200S Maint Manual

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

Page 3: AMT-200S Maint Manual

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

Page 4: AMT-200S Maint Manual

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

Page 5: AMT-200S Maint Manual

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

Page 6: AMT-200S Maint Manual

MAINTENANCE MANUAL

AMT 200S SECTION:1

MM - 200-25

Page 1.5

August 10, 2004 - Rev. 8

1.13 Vent holes and drains

Page 7: AMT-200S Maint Manual

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

Page 8: AMT-200S Maint Manual

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

Page 9: AMT-200S Maint Manual

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)

Page 10: AMT-200S Maint Manual

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

Page 11: AMT-200S Maint Manual

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)

Page 12: AMT-200S Maint Manual

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

Page 13: AMT-200S Maint Manual

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

Page 14: AMT-200S Maint Manual

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

Page 15: AMT-200S Maint Manual

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

Page 16: AMT-200S Maint Manual

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

Page 17: AMT-200S Maint Manual

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

Page 18: AMT-200S Maint Manual

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

Page 19: AMT-200S Maint Manual

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

Page 20: AMT-200S Maint Manual

MAINTENANCE MANUAL

AMT 200S SECTION:1

MM - 200-25

Brake System

Page 1.19

August 10, 2004 - Rev. 8

Page 21: AMT-200S Maint Manual

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

Page 22: AMT-200S Maint Manual

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°)

Page 23: AMT-200S Maint Manual

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

Page 24: AMT-200S Maint Manual

MAINTENANCE MANUAL

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MM - 200-25

Aileron Controls

Page 1.23

August 10, 2004 - Rev. 8

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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

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MM - 200-25

Elevator Control

Page 1.25

August 10, 2004 - Rev. 8

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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

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MAINTENANCE MANUAL

AMT 200S SECTION:1

MM - 200-25

Rudder Control

Page 1.27

August 10, 2004 - Rev. 8

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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

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MAINTENANCE MANUAL

AMT 200S SECTION:1

MM - 200-25

Trim Control System

Page 1.29

August 10, 2004 - Rev. 8

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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

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MAINTENANCE MANUAL

AMT 200S SECTION:1

MM - 200-25

Airbrake Control System

Figure 2

Page 1.31

August 10, 2004 - Rev. 8

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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

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MM - 200-25

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August 10, 2004 - Rev. 8

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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

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MM - 200-25

Main Landing Gear Control System

Page 1.35

August 10, 2004 - Rev. 8

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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

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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

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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

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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.

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August 10, 2004 - Rev. 8

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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

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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:

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MM - 200-25

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August 10, 2004 - Rev. 8

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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

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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

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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

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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

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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

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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

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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.

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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.

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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.

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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

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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.

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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

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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

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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.

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FIRST EVERY

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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

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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

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.

14.

15.

16.

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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

X X X

X X X

X X X

X X

01.

02.

03.

04.

05.

06.

07.

08.

09.

10.

11.

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FIRST EVERY

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h h h h year

MM - 200-25

LANDING GEAR

X X X

X X X

X X X

X X X

X

X X X

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.

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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.

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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

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 X

01.

02.

03.

04.

05.

06.

07.

08.

09.

10.

11.

12.

13.

14.

15.

16.

17.

Page 5.14

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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

X X X

X X X

X X

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

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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

X X X

X

X

X X X

X X

X

X X X

X

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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

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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.

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MAINTENANCE MANUAL

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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

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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

X X X

X X X

X X X

X X X

GENERAL

01.

02.

03.

04.

05.

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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

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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

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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.

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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.

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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

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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