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

AMT 200S

MAINTENANCE

MANUAL

200-25

AMT 200S MAINTENANCE MANUAL 200-25
MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1

MAINTENANCEMANUAL AMT 200S

SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1

SECTION 1 - DESCRIPTIONS, SYSTEMS, RIGGINGS AND PLACARDS

1. Motorglider Characteristics

1.1 Basic Dimensions

Wing span Wing span with winglets (optional) Wing span (wings folded) Length Maximum height

1.2 Wings

Wing surface (area) Dihedral Profile Angle of incidence Wing torsion

1.3 Ailerons

Percent to wing chord (depth) Aileron span Aileron surface (area)

1.4 Airbrakes

Position

Airbrake span

Type

1.5 Horizontal Stabilizer

Horiz. stabilizer span Horiz. stabilizer surface (area) Elevator surface Horiz. stabilizer - angle of incidence

57.32 ft (17.47 m)

57.97 ft (17.67 m)

33.30 ft (10.15 m) 26.50 ft (8.08 m) 6.33 ft (1.93 m)

201.29 Sqft (18.70 m 2 ) 2° 30' Naca 64 3 618

-2°

30%

10.24 ft (3.12 m) 7.32 Sqft (0.68 m 2 )

at 45% of wing chord 4.76 ft (1.45 m) Schempp hirth on upper wing surface

12.07 ft (3.68 m)

31.21 Sqft (2.90 m 2 )

10.23 Sqft (0.95 m 2 )

-1°

Page 1.1

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SECTION:1

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1.6 Vertical Empennage

Vertical empennage surface (area) Rudder surface (area)

1.7 Landing Gear

22.93 Sqft (2.13m 2 ) 7.42 Sqft (0.69m 2 )

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/cm 2 ) >0°C Pressure 145 psi (10,19 kg/cm 2 ) <0°C

Main wheel tire:

330 x 130 (5.00-4) pressure 45 psi (3.2 kg/cm 2 )

Tail wheel tire:

210 x 65 CR17 pressure 36.2 psi (2.5 kg/cm 2 )

Main landing gear track:

Distance between front and rear landing gear axes:

1.8 Power Plant

9.18 ft (2.80 m)

16.51 ft (5.35 m)

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

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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

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SECTION:1

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1.12 Air Pressure Ports

A M T 2 0 0 S SECTION:1 1.12 Air Pressure Ports 1. Dynamic air pressure

1. Dynamic air pressure port

2. Static air pressure port

3. Total energy

Page 1.4

August 10, 2004 - Rev. 8

MM - 200-25

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1.13 Vent holes and drains

A M T 2 0 0 S SECTION:1 1.13 Vent holes and drains Page 1.5 MM

Page 1.5

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AMMETER/CHT

2. Electrical Diagram

11 CHT PP1A4 88 ENGINE RELAY 2A RED PP17A22 44 2A BLACK PP18A22 55 ENGINE
11
CHT
PP1A4
88
ENGINE RELAY
2A
RED
PP17A22
44
2A
BLACK
PP18A22
55
ENGINE GROUND
BATTERY
PP1D10
PP3A4N
PP1B10
SHUNT
PP2A4N
PP3B10N
K1
MAIN
AIRCRAFT END
BUS BAR
GROUND
PP6A20
PP4A10
MAIN/SOARING
PP1C10
MASTER
K2
SOARING
SOARING
PP5A10
PP8A20N
PP7A20

MAIN BUSMASTER K2 SOARING SOARING PP5A10 PP8A20N PP7A20 BAR SOARING BUS BAR BATTERY DIAGRAM (Motorgliders s/n

BAR

SOARING BUSK2 SOARING SOARING PP5A10 PP8A20N PP7A20 MAIN BUS BAR BAR BATTERY DIAGRAM (Motorgliders s/n 200.119, 200.122,

BAR

BATTERY DIAGRAM

(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)

PP1A4 11 ENGINE RELAY CHT 88 2A BLACK PP17A22 44 2A RED PP18A22 55 K1
PP1A4
11
ENGINE RELAY
CHT
88
2A
BLACK
PP17A22
44
2A
RED
PP18A22
55
K1
BATTERY
MAIN
30A
PP3A4N
PP1D10
PP1B10
PP4A10
MAIN
SHUNT
SHUNT
PP2A4N
PRESSURE
SWITCH
HOUR METER
FUSE
LINE
+
E7A22
E6A22
BUS BAR
AIRCRAFT
PP6A20
GROUND
2A
-
E8A22
K2
PP1C10
MAIN/SOARING
SOARING
20A
PP5A10
MASTER
SOARING
SOARING
HOUR METER
SPARE
E9A22
+
PP7A20
2A
-
PP8A20N
E10A22
AMMETER/CHT

ENGINE

BATTERY DIAGRAM

(Motorgliders s/n 200.128 to 200.132)

Page 1.6

MAIN BUS

BAR

SOARING

BUS BAR

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MAINTENANCEMANUAL AMT 200S

SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
1 CHT STARTER RELAY PP1A4 8 2A BLACK PP17A22 4 2A RED PP18A22 5 K1
1
CHT
STARTER RELAY PP1A4
8
2A
BLACK
PP17A22
4
2A
RED
PP18A22
5
K1
BATTERY
MAIN
BUS BAR
30A
GROUND
PP3A4N
PP1D10
PP1B10
PP4A10
MAIN
BUS
PP2A4N
SHUNT
OIL PRESSURE
10A
SWITCH
PP14A16
HOUR METER
FUSE
FIREWALL
LINE
MASTER
+
E7A22
E6A22
SWITCH
PP8A20N
PP6A20
PP15A16N
2A
-
E8A22
ON
K2
PP1C10
OFF
BATTERY CHARGER PLUG
HOUR METER
+
E9A22
2A
-
E10A22
PP1A4
TO STARTER RELAY
AMMETER/CHT

BATTERY DIAGRAM

MAIN BUS

BAR

(Motorglider s/n 200.133 and on) STARTER RELAY PP1A4 2A BLACK 2A RED K1 BATTERY MAIN
(Motorglider s/n 200.133 and on)
STARTER RELAY PP1A4
2A
BLACK
2A
RED
K1
BATTERY
MAIN
BUS BAR
30A
GROUND
PP3A4N
PP1D10
PP1B10
PP4A10
MAIN
BUS
PP2A4N
SHUNT
OIL PRESSURE
10A
SWITCH
PP14A16
HOUR METER
FUSE
FIREWALL
LINE
MASTER
+
E7A22
E6A22
SWITCH
PP8A20N
PP6A20
PP15A16N
2A
-
E8A22
ON
K2
PP1C10
HOUR METER
OFF
BATTERY CHARGER PLUG
+
E9A22
2A
-
E10A22
PP1A4
TO STARTER RELAY

BATTERY DIAGRAM

Optional Configuration

PP1A4 TO STARTER RELAY BATTERY DIAGRAM Optional Configuration MAIN BUS BAR Page 1.7 MM - 200-25

MAIN BUS

BAR

Page 1.7

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MAINTENANCEMANUAL AMT 200S

SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1

STARTER

M
M
K3 PP1A4 KK1A4 KK5A22 5A KK3A20 KK2A20 STARTER STARTER KK6A20N
K3
PP1A4
KK1A4
KK5A22
5A
KK3A20
KK2A20
STARTER
STARTER
KK6A20N

BATTERY

ALARM
ALARM

LANDING GEAR

MAIN BUS BAR

JK3A18
JK3A18

MAGNETO A

JK4A18
JK4A18

JK1A18

IGNITION A

IGNITION B

JK2A18

MAGNETO B

STARTER AND MAGNETO DIAGRAM

(Motorgliders s/n 200.119, 200.122 and on)

G G K4 30A MAIN KK3A20 B BUS BAR ALTERNATOR C PP11A20 R E7A22 HOUR
G
G
K4
30A
MAIN
KK3A20
B
BUS
BAR
ALTERNATOR
C
PP11A20
R
E7A22
HOUR METER
25V
ALTERNATOR
22.000 uf

ALTERNATOR DIAGRAM

(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)

Page 1.8

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SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
K4 K4 30A PP9A10 G ALTERNATOR ALTERNATOR G PP10A10 B CC R 5A PP13A20 FUSE
K4
K4
30A
PP9A10
G
ALTERNATOR
ALTERNATOR
G
PP10A10
B
CC
R
5A
PP13A20
FUSE LINE
25V
ALTERNATOR
22.000
22.000
uf
uf
PP12A20N
VOLTAGE REGULADOR
PP11A20

ALTERNATOR DIAGRAM

(Motorglider s/n 200.128 and on)

MAIN BUS

BAR

F1A22DIAGRAM (Motorglider s/n 200.128 and on) MAIN BUS BAR     F2A22 TURN BANK   F3A22N

   

F2A22

TURN BANK

 

F3A22N

 

PILOT

   

F11A22

TURN BANK

 

F12A22N

 

COPILOT

DIREC.

 

F4A22

GYRO

F6A22N

PILOT

DIREC.

 

F13A22

GYRO

 

F15A22N

 

COPILOT

ATT

 

F8A22

INDICATOR

 

F8A22N

 

PILOT

ATT

 

F17A22

INDICATOR

 

F18A22N

 

COPILOT

T&B
T&B

2A

F10A22INDICATOR   F18A22N   COPILOT T&B 2A T&B 2A F3A22 GD 2A F14A22 GD 2A ATT

T&B
T&B

2A

F3A22F18A22N   COPILOT T&B 2A F10A22 T&B 2A GD 2A F14A22 GD 2A ATT F7A22 2A

GD
GD

2A

F14A22  COPILOT T&B 2A F10A22 T&B 2A F3A22 GD 2A GD 2A ATT F7A22 2A F16A22

GD
GD

2A

ATT

F7A22T&B 2A F10A22 T&B 2A F3A22 GD 2A F14A22 GD 2A ATT 2A F16A22 2A FLIGHT

2A F10A22 T&B 2A F3A22 GD 2A F14A22 GD 2A ATT F7A22 2A F16A22 2A FLIGHT

2A

F16A222A F10A22 T&B 2A F3A22 GD 2A F14A22 GD 2A ATT F7A22 2A 2A FLIGHT INSTRUMENT

T&B 2A F3A22 GD 2A F14A22 GD 2A ATT F7A22 2A F16A22 2A FLIGHT INSTRUMENT DIAGRAM

2A

FLIGHT INSTRUMENT DIAGRAM

(Motorgliders s/n 200.119, 200.122 to 200.132)

MAIN BUS BAR

SOARING BUS

Page 1.9

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MAINTENANCEMANUAL AMT 200S

SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1

F1A22MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1     F2A22 TURN BANK   (OPTIONAL)

   

F2A22

TURN BANK

 

(OPTIONAL)

F3A22N

 

PILOT

   

F11A22

TURN BANK

 

(OPTIONAL)

F12A22N

 

COPILOT

DIREC.

 

F4A22

GYRO

 

(OPTIONAL)

F6A22N

 

PILOT

 

DIREC

 

F13A22

GYRO

 

(OPTIONAL) .

F15A22N

 

COPILOT

 

ATT

 

F8A22

INDICATOR

 

(OPTIONAL)

F8A22N

 

PILOT

 

ATT

 

F17A22

INDICATOR

 

(OPTIONAL)

F18A22N

 

COPILOT

T&B
T&B

2A

F10A22  (OPTIONAL) F18A22N   COPILOT T&B 2A T&B 2A F3A22 GD 2A F14A22 GD 2A ATT

T&B
T&B

2A

F3A22F18A22N   COPILOT T&B 2A F10A22 T&B 2A GD 2A F14A22 GD 2A ATT F7A22 2A

GD
GD

2A

F14A22  COPILOT T&B 2A F10A22 T&B 2A F3A22 GD 2A GD 2A ATT F7A22 2A F16A22

GD
GD

2A

ATT

F7A22T&B 2A F10A22 T&B 2A F3A22 GD 2A F14A22 GD 2A ATT 2A F16A22 2A FLIGHT

2A F10A22 T&B 2A F3A22 GD 2A F14A22 GD 2A ATT F7A22 2A F16A22 2A FLIGHT

2A

F16A222A F10A22 T&B 2A F3A22 GD 2A F14A22 GD 2A ATT F7A22 2A 2A FLIGHT INSTRUMENT

T&B 2A F3A22 GD 2A F14A22 GD 2A ATT F7A22 2A F16A22 2A FLIGHT INSTRUMENT DIAGRAM

2A

FLIGHT INSTRUMENT DIAGRAM

(Motorgliders s/n 200.133 and on)

Page 1.10

July 17, 2007 - Rev. 11

MAIN BUS BAR

MM - 200-25

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
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MAINTENANCEMANUAL AMT 200S

SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
LEFT GEAR LEFT WING MICRO SWITCH CONNECTOR GW3C22 GW3A22 NO 11 5 6 GW2D22N C
LEFT GEAR
LEFT WING
MICRO SWITCH
CONNECTOR
GW3C22
GW3A22
NO
11
5
6
GW2D22N
C
22
4
GW2A22N
GW5B22
NC
33
6
RIGHT GEAR
RIGHT WING
MICRO SWITCH
CONNECTOR
GW1C22
GW1A22
NO
11
5
5
GW2E22N
C
22
4
GW5C22
NC
33
6
AIR BRAKE
MICRO SWITCH
NO
GW2B22N
C
GW1B22
GW2C22N
NC
GW6A22
GEAR UP
MICRO SWITCH
NO
GW4A22
C
4
GW5A22
NC
GW5D22
GW4B22
GW1B22
RIGHT GEAR
LEFT GEAR
DOWN
DOWN
5
3
GW3B22
2A
GW12A22
GEAR LIGHT
4
SOARING
BUS
RETRACTED OR
GW11A22N
GW10A22
IN TRANSIT
1
TEST
GW7C22
2
1
PW2A22
10
STARTER
LOW
ENGAGED
BATTERY
KK4A22
12
KK5A22
STARTER
13
PW3A22N
GW9A22
2
CANCEL
GW7B22
2A
GW7A22
3
GEAR WARN
2A
PW1A22
9
LOW BATT
PW4A22N
11
SOARING
BUS

WARNING SYSTEM DIAGRAM

(LANDING GEAR, AIRBRAKE, STARTER ENGAGED, LOW BATTERY) (Motorgliders s/n 200.119, 200.122 to 200.132)

MM - 200-25

Page 1.11

July 17, 2007 - Rev. 11

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
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SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
LEFT GEAR LEFT WING MICRO SWITCH CONNECTOR GW3C22 GW3A22 NO 1 5 6 GW2D22N C
LEFT GEAR
LEFT WING
MICRO SWITCH
CONNECTOR
GW3C22
GW3A22
NO
1
5
6
GW2D22N
C
2
4
GW2A22N
GW5B22
NC
3
6
RIGHT GEAR
RIGHT WING
MICRO SWITCH
CONNECTOR
GW1C22
GW1A22
NO
1
5
5
GW2E22N
C
2
4
GW5C22
NC
3
6
W
A
R
AIR BRAKE
MICRO SWITCH
N
I
NO
N
G
GW2B22N
C
S
GW1B22
GW2C22N
Y
NC
S
T
E
GW6A22
GEAR UP
M
MICRO SWITCH
NO
U
N
GW4A22
I
C
4
T
GW5A22
NC
GW5D22
GW4B22
GW1B22
RIGHT GEAR
LEFT GEAR
M
DOWN
5
3
DOWN
GW3B22
A
I
2A
N
GW12A22
B
4 GEAR LIGHT
U
S
RETRACTED OR
GW11A22N
GW10A22
1
IN TRANSIT
TEST
W
GW7C22
A
R
2
1
PW2A22
N
10
I
STARTER
LOW
N
ENGAGED
BATTERY
KK4A22
12
G
S
KK5A22
STARTER
13
Y
S
PW3A22N
GW9A22
T
2
E
CANCEL
M
GW7B22
U
GW7A22
N
3
I
T
GW7C22
PW1A22
9
2A
2A
PW4A22N
11
2A
GN16A22
15
7
GW17A22
8
SENSOR
GW18A22N
14
GW13A 22
GW15A 22

GEAR LIGHT

GEAR WARN

LOW BATT

COOLANT LEVEL

WARNING SYSTEM DIAGRAM

(LANDING GEAR, AIRBRAKE, STARTER ENGAGED, LOW BATTERY, COOLANT LEVEL) (Motorgliders s/n 200.133 and on)

Page 1.12

July 17, 2007 - Rev. 11

MM - 200-25

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SECTION:1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
E2A22 1 OILTEMP. SENDER E3A22 OIL PRESSURE 3 OIL TEMP./ SENDER PRESSURE E8A22N E1A22 INDICATOR
E2A22
1
OILTEMP. SENDER
E3A22
OIL PRESSURE
3
OIL TEMP./
SENDER
PRESSURE
E8A22N
E1A22
INDICATOR
4
2A
MAIN
E4A22N
BUS
5

GND

BATTERY

OIL TEMPERATURE / PRESSURE DIAGRAM - Standard configuration

OIL TEMPERATURE / PRESSURE AND RPM INDICATION
OIL TEMPERATURE / PRESSURE AND RPM INDICATION

Optional Configuration

2A F1A22 2A F3A22 2A F5A22 5A RV1A18RV1A18 B VHF/COMM RVZA18N A 3A SN1A20 B
2A
F1A22
2A
F3A22
2A
F5A22
5A
RV1A18RV1A18
B
VHF/COMM
RVZA18N
A
3A
SN1A20
B
TRANSPONDER
SN2A20N
A
2A
JN3A22
B
ALTITUDE
BLACK
ENCODER
A

TURN AND BANK (OPTIONAL)

INTERCOM (OPTIONAL)

ATT INDICATOR (OPTIONAL)

VHF/COMM

TRANSPONDER

ALTITUDE ENCODER

AVIONICS DIAGRAM - Standard configuration

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Page 1.13

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5A Q2A18 Q1A18 Q3A18N FUEL PUMP LEFT AUX. POWER 5A PM2A20N PM1A20 RIGHT AUX. POWER
5A
Q2A18
Q1A18
Q3A18N
FUEL PUMP
LEFT AUX. POWER
5A
PM2A20N
PM1A20
RIGHT AUX. POWER
PM2B20N
PM2B20

FUEL PUMP

AUX. POWER

AVIONICS DIAGRAM - Standard configuration

2A Q4A22 DB15 RED 1 Q4C22 1 YELLOW Q5A22 2 Q5B22 1 2 SENDER BLACK
2A
Q4A22
DB15
RED
1 Q4C22
1
YELLOW
Q5A22
2 Q5B22
1
2
SENDER
BLACK
FUEL
Q7B22N
3 Q7E22N
5
3
LEFT
LEVEL
Q7A22N
INDICATOR
DB15
RED
3
Q4E22
1
1
YELLOW
Q6A22
Q6B22
2
2
SENDER
BLACK
3 Q7E22N
3
RIGHT

FUEL INDICATOR

FUEL LEVEL DIAGRAM - Standard configuration

FUEL INDICATOR FUEL LEVEL DIAGRAM - Standard configuration FUEL LEVEL DIAGRAM Optional Configuration Page 1.14 July

FUEL LEVEL DIAGRAM

Optional Configuration

Page 1.14

DIAGRAM - Standard configuration FUEL LEVEL DIAGRAM Optional Configuration Page 1.14 July 17, 2007 - Rev.
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3. Ground Connecting Straps 4 5 5 4 4 4 4 6 5 2 4
3. Ground Connecting Straps
4
5
5
4
4
4
4
6
5
2
4
3
1
4
2
4
4
5
STRAP
IPCREFERENCE
PAGE
ITEM
6
1 IPC FIGURE 05
2.16
2-3-43-66
2 IPC FIGURE 13
2.44/2.45/2.46/2.47/2.48
18-26-44-90
3 IPC FIGURE 15
2.58
19-26
2
4 IPC FIGURE 16
2.62
3-26-33-60
5 IPC FIGURE 18
2.68
11-27
6 IPC FIGURE 20
2.74
66
Ground Connecting Straps Table

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4. Fuel System

Each wing has one aluminum fuel tank located between the leading edge and the main gear wheel well. The tanks are independent and the fuel level is indicated by a fuel quantity transmitter.

There is a three-position selector valve to select the tank in use and cut off the fuel.

   

USABLE

 

TOTAL

Left Wing Tank

11.62

US gallons (44 litres)

11.89

US gallons (45 litres)

Right Wing Tank

11.62

US gallons (44 litres)

11.89

US gallons (45 litres)

Total Capacity

23.24

US gallons (88 litres)

23.78

US gallons (90 litres)

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

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4 3 5 5 10 2 2 5 5 6 5 FIREWALL 5 9 5
4
3
5
5
10
2
2
5
5
6
5
FIREWALL
5
9
5
8
FUEL RETURNING LINE
TO FUEL TANKS
5
5
7
7
7

CARBURETOR

VENT AND

DRAIN TUBE

Fuel System

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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.

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Brake System

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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.

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6.2.5 Record the neutral position in a table as the example below

 

AILERON (LH)

AILERON (RH)

Neutral

α(+ 1°)

ß(+ 1°)

Up

   

Down

   

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.

 

AILERON (LH)

AILERON (RH)

Neutral

0° ± 1°

0° ± 1°

Up

15° ± 1°

15° ± 1°

Down

15° ± 1°

15° ± 1°

Page 1.21

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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

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Aileron Controls
Aileron Controls
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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 on section 3.

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Elevator Control

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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

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Rudder Control

Page 1.27

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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.

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Trim Control System

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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.

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Airbrake Control System Figure 2

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MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1 Figure 2 1- Airbrake control lever 2-

Figure 2

1-

Airbrake control lever

2-

Center console

3-

Airbrake control link rod

4-

Stop screw

5-

Airbrake micro switch

6.38 ± 0.31 in
6.38 ± 0.31 in

Page 1.32

Figure 3

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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

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Main Landing Gear Control System

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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.

times. Note: Do the procedure above for the two main gears. 1- Link rod 5- Control

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

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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.

it with the lock nut to obtain the correct rigging position. Detail A 1- Link rod

Detail A

lock nut to obtain the correct rigging position. Detail A 1- Link rod 6- Stop screw

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

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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.

nut of the control link rod and lock it using a lock washer. 1- Landing gear

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

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MAINTENANCEMANUAL AMT 200S

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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

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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

MAINTENANCEMANUAL A M T 2 0 0 S SECTION:1
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MAINTENANCEMANUAL AMT 200S

SECTION:1

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ln order to identify the main subassemblies of the motorglider AMT-200S Super Ximango, refer to the table below:

of the motorglider AMT-200S Super Ximango, refer to the table below: Page 1.41 MM - 200-25

Page 1.41

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Page 1.42

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13. Placards 25-B 24 19 30-B 32 5-A 23 47 21-A 31 22 4 28
13.
Placards
25-B
24
19
30-B
32
5-A
23
47
21-A
31
22
4
28
16
3
27
34
16
17
18
36
29
2
33
35
1
6
10
8
9
11
7

Standard version

25

21 5 24 19 30 21
21
5
24
19
30
21
22 32 31 4 16 3 27 34 28 16 17 18 36 29 35
22
32
31
4
16
3
27
34 28
16
17
18 36
29
35
2
33
1
6
23
10
8
9
11
7

Optional - Factory Incorporated Only

Page 1.43

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SECTION: 1

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25C

24 30 19 31 43 44 32 23 22 44 45 21A 5 4 3
24
30
19
31
43
44
32
23
22
44
45
21A
5
4
3
27
34
46
17
18
36
29
2
33
35
1
6 10 8 9 11 7
6
10
8
9
11
7

Optional - Factory Incorporated Only

44

25D

24 30-B 19 48 31 43 47 32-B 23 22 44 45-B 21-A 5-A 46
24
30-B
19
48
31
43
47
32-B
23
22
44
45-B
21-A
5-A
46
3
27 4
34
17
18 36
29
2
33
35
1
6
10
8
9
11
7

Optional - Factory Incorporated Only

Page 1.44

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5-A 23 21-A 25-E 24 22 30-B 19 31 32-C 3 4 27 34 17
5-A
23
21-A
25-E
24
22
30-B
19
31
32-C
3
4
27
34
17
18 36
29
2
33
35
1
6
10
8
9
11
7
5-A
23
21-A

Optional - Factory Incorporated Only

25-G

21-A 5-A 23 24 22 30-B 38 19 31 32-E 3 27 4 34 17
21-A
5-A
23
24
22
30-B
38
19
31
32-E
3
27 4
34
17
18
36
2
33
1
6
10
8
9
11
7
5-A
23
21-A

Optional - Factory Incorporated Only

Page 1.45

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25G

24 30-B 19 43-A 31 AIRFRAMETIME 21-A 44-A ENGINE TIME 44-A 22 32-E 5-A 23
24
30-B
19
43-A
31
AIRFRAMETIME
21-A
44-A
ENGINE TIME
44-A
22
32-E
5-A
23
48-A
3
27 4
34
17
18 36
29
2
33
35
1
6
10
8
9
11
7

Optional - Factory Incorporated Only

25H

24 30-B 19 43-A 31 21-A 44- A 22 4 4-A 3 32-E 47 23
24
30-B
19
43-A
31
21-A
44-
A
22
4
4-A
3
32-E
47
23
5-A
4
48-A
27
3
4
17
18
36
29
2
33
35
1
6
10
8
9
11
7

Optional - Factory Incorporated Only

Page 1.46

MAINTENANCE MANUAL A M T 2 0 0 S SECTION: 1
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25-I

5-A 23 21-A 22 24 38 30-B 19 31 32-F 3 4 27 34 17
5-A
23
21-A
22
24
38
30-B
19
31
32-F
3
4
27
34
17
18
36
29
2
1 33
35
6
10
8
9
11
7
23
5-A
21-A

Optional - Factory Incorporated Only

25-J

23 21-A 5-A 22 24 30-B 19 43-A 31 32-G 44-A 44-A 49 49 39
23
21-A
5-A
22
24
30-B
19
43-A
31
32-G
44-A
44-A
49
49
39
39
50
37
37
51
3
27 4
34
17
18
36
29
2
1 33
35
6
1 0
8
9
1
1
7
23
5-A
21-A

Optional - Factory Incorporated Only

Page 1.47

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25-K 22 24 30-B 19 32-H 38 21-A 23 3 5-A 27 4 34 17
25-K
22
24
30-B
19
32-H
38
21-A
23
3
5-A
27 4
34
17
18
36
29
2
33
35
1
6
1 0
8
9
1
1
7

Optional - Factory Incorporated Only

25-L

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

Optional - Factory Incorporated Only

Page 1.48

MAINTENANCEMANUAL A M T 2 0 0 S SECTION: 5
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MAINTENANCEMANUAL AMT 200S

SECTION: 5

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SECTION 5 - MAINTENANCE CHECKS

1.

External Visual Inspection

Inspect the aircraft before every flight to prevent failures or even accidents.

1.1

External Inspection

(1)

- Extend the airbrakes.

- Make sure that the ignition switch OFF.

Cabin

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.

Página 5.1

MAINTENANCEMANUAL A M T 2 0 0 S SECTION: 5
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- 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.

Página 5.2

Agosto 10, 2004 - Rev. 8

MM - 200-25

MAINTENANCEMANUAL A M T 2 0 0 S SECTION: 5
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- 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.

MM - 200-25

Página 5.3

July 17, 2007 - Rev. 11

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OPERATIONAL

FIRST

 

EVERY

 

ITEM

 

25

50

100

200

1

 

INSPECTION

h

h

h

h

year

 

NOTE: Before checking oil level, turn propeller over several times to ensure that crankcase oil has been returned to the oil tank.This process finishes when air is returning back to the oil tank and can be noticed by a murmur from the open oil tank.

         

1.

Do engine run-up and record all engine parameters.

X

X

X

X

2.

Check electric and engine-driven fuel pumps and fuel tank selector.

X

X

X

X

3.

Check fuel quantity and recalibrate fuel system, if necessary.

X

4.

Check alternator output.

 

X

X

X

X

5.

Check carburetor heat air control.

X

X