AMT 200S

MAINTENANCE
MANUAL
200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

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°

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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°C
Pressure 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)

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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.

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

1.12 Air Pressure Ports

1. Dynamic air pressure port

2. Static air pressure port
3. Total energy

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

1.13 Vent holes and drains

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

2. Electrical Diagram

AM METER/CHT
1
CHT
PP1A4 8
ENGINE RELAY 2A
RED PP17A22 4
2A
BLACK PP18A22 5
ENGINE GROUND BATTERY
PP3A4N PP1D10 PP1B10

SHUNT
PP2A4N

PP3B10N
K1
MAIN 30A
AIRCRAFT END PP4A10 MAIN BUS
BAR
BUS BAR
GROUND

PP6A20

MAIN/SOARING
PP1C10
MASTER

K2
SOARING SOARING 20A
PP5A10 SOARING BUS
BAR

PP8A20N

PP7A20

BATTERY DIAGRAM
(Motorgliders s/n 200.119, 200.122, 200.123, 200.124, 200.126 and 200.127)
AMMETER/CHT

PP1A4 1
ENGINE RELAY CHT

2A 8
BLACK PP17A22
4
RED 2A PP18A22
5

K1
BATTERY MAIN
PP1D10 PP1B10 30A
ENGINE PP3A4N PP4A10

MAIN
PP2A4N SHUNT PRESSURE MAIN BUS
HOUR METER SWITCH BAR
FUSE
LINE
BUS BAR AIRCRAFT PP6A20 + E7A22 E6A22

GROUND 2A
-
E8A22
PP1C10 K2
MAIN/SOARING SOARING
20A
PP5A10
MASTER
SOARING
SOARING SOARING
BUS BAR
HOUR METER
SPARE
E9A22
PP7A20
+
2A
PP8A20N -
E10A22

BATTERY DIAGRAM
(Motorgliders s/n 200.128 to 200.132)

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August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

AMMETER/CHT
CHT
STARTER RELAY PP1A4
2A 8
BLACK PP17A22
4
RED 2A PP18A22
5

K1
BAT TERY MAIN
BUS BAR
GROUND PP1B10 30A
PP3A4N PP1D10 PP4A10

MAIN
BUS
PP2A4N SHUNT OIL PRESSURE
10A
PP14A16 HOUR METER SWITCH
FIREWALL FUSE
MASTER LINE
E7A22
PP8A20N SWITCH PP6A20 + E6A22
PP15A16N 2A
-
E8A22
ON PP1C10 K2 MAIN BUS
OFF BAR
BATTERY CHARGER PLUG

HOUR METER

E9A22
+
2A
-
E10A22

PP1A4
TO STARTER RELAY

BATTERY DIAGRAM
(Motorglider s/n 200.133 and on)

STARTER RELAY PP1A4 2A

BLACK

RED 2A

K1
BATTERY
BUS BAR MAIN
GROUND PP1B10 30A
PP3A4N PP1D10 PP4A10
MAIN
BUS
PP2A4N SHUNT OIL PRESSURE
10A
PP14A16 HOUR METER SWITCH
FIREWALL FUSE
MASTER LINE
E7A22
PP8A20N SWITCH PP6A20 + E6A22
PP15A16N 2A
-
E8A22
ON PP1C10 K2 MAIN BUS
OFF HOUR METER BAR
BATTERY CHARGER PLUG
E9A22
+
2A
-
E10A22

PP1A4
TO STARTER RELAY

BATTERY DIAGRAM
Optional Configuration
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 MAINTENANCE MANUAL
AMT 200S SECTION:1

STARTER

K3
BAT TERY LA NDING GEAR
PP1A4 KK1A4 KK5A 22 ALARM

KK3 A20 KK2A20 5A

MAI N BUS BAR

STARTER STARTER

KK6A 20N

JK3A 18 JK1A1 8
IGNIT ION A
MAGNET O A
JK2A18
IGNIT ION B

JK4A 18

MAGNET O B

STARTER AND MAGNETO DIAGRAM

(Motorgliders s/n 200.119, 200.122 and on)

G
G
K4 30A MAIN
KK3A20
B BUS
ALTERNATOR BAR

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)

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July 17, 2007 - Rev. 11 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

K4
30A
PP9A10 MAIN BUS
G BAR
ALTERNATOR ALTERNATOR
G
VOLTAGE REGULADOR

PP10A10
B

PP11A20
C
R 5A PP13A20

FUSE LINE
25V
ALTERNATOR
22.000 uf
PP12A20N

ALTERNATOR DIAGRAM
(Motorglider s/n 200.128 and on)

F2A22 F1A22 T&B

TURN BANK
2A
F3A22N

PILOT

F11A22 F10A22 T&B

TURN BANK
2A
F12A22N

COPILOT
MAIN BUS BAR

F4A22 F3A22 GD
DIREC.

GYRO 2A
F6A22N

PILOT

F13A22 F14A22 GD
DIREC.

GYRO 2A
F15A22N
COPILOT

ATT
F8A22 F7A22
ATT

INDICATOR 2A
F8A22N
PILOT SOARING BUS

F17A22 F16A22
ATT

INDICATOR 2A
F18A22N
COPILOT

FLIGHT INSTRUMENT DIAGRAM

(Motorgliders s/n 200.119, 200.122 to 200.132)

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

F2A22 F1A22 T&B

TURN BANK
(OPTIONAL) 2A
F3A22N

PILOT

F11A22 F10A22 T&B

TURN BANK
(OPTIONAL) 2A
F12A22N

COPILOT

F4A22 F3A22 GD
DIREC.
GYRO
(OPTIONAL) 2A
F6A22N

PILOT

F13A22 F14A22 GD
DIREC
GYRO MAIN BUS BAR
(OPTIONAL) . 2A
F15A22N
COPILOT

ATT
F8A22 F7A22
ATT
INDICATOR
(OPTIONAL) 2A
F8A22N
PILOT

F17A22 F16A22
ATT
INDICATOR
(OPTIONAL) 2A
F18A22N
COPILOT

FLIGHT INSTRUMENT DIAGRAM

(Motorgliders s/n 200.133 and on)

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July 17, 2007 - Rev. 11 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

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

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 5 3 DOWN
GW3B22

2A
GW12A22

GEAR LIGHT
4
SOARING
BUS

RETRACTED OR GW10A22
GW11A22N
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
SOARING 11
BUS

WARNING SYSTEM DIAGRAM

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

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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
AIR BRAKE R
M ICRO SWITC H N
I
NO
N
G
GW2B22N
C
GW1B22 GW2C22N
S
Y
NC S
T
GEAR UP
GW6A22 E
M ICRO SWITC H
M

NO U
N
GW4A22 I
C 4
T
GW5A22
NC
GW5D22

GW4B22

GW1B22
RIGHT GEAR LEFT GEAR
DOWN 5 3 DOWN M
GW3B22
A
2A
I
GW12A22 N
GEAR LIGHT

4 GEAR LIGHT B
U
S
RETRACTED OR GW11A22N GW10A22
IN TRANSIT 1
TEST
GW7C22 W
A
R
2 1 PW2A22
10
N
I
STARTER LOW
ENGAGED BATTERY N
KK4A22
12 G

KK5A22 S
STARTER 13 Y
S
PW3A22N GW9A22
2 T
CANCEL E
GW7B22 M

U
GW7A22 N
3
I
T
GW7C22

PW1A22
9
2A
GEAR WARN
2A
LOW BATT

PW4A22N
11

2A
GN16A22
COOLANT LEVEL
GW 13A 22

GW 15A 22

15

7
GW17A22
8
SENSOR
GW18A22N
14

WARNING SYSTEM DIAGRAM

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

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

1
E2A22 OIL TEMP. SENDER

3 E3A22 OIL PRESSURE

OIL TEMP./ SENDER
PRESSURE E8A22N
INDICATOR 4
E1A22
2A MAIN
5
E4A22N BUS

GND
BATTERY

OIL TEMPERATURE / PRESSURE DIAGRAM - Standard configuration

OIL TEMPERATURE / PRESSURE AND RPM INDICATION

Optional Configuration

2A
F1A22
TURN AND BANK (OPTIONAL)

2A
F3A22
INTERCOM (OPTIONAL)

2A
F5A22
ATT INDICATOR (OPTIONAL)

5A
RV1A18
B RVZA18N
VHF/COMM
VHF/COMM
A

3A
SN1A20 TRANSPONDER
B SN2A20N
TRANSPONDER
A

2A
JN3A22
ALTITUDE B ALTITUDE ENCODER
BLACK
ENCODER A

AVIONICS DIAGRAM - Standard configuration

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

5A
Q3A18N Q2A18 Q1A18
FUEL PUMP FUEL PUMP

LEFT AUX. POWER 5A

PM2A20N PM1A20
AUX. POWER

RIGHT AUX. POWER

PM2B20N PM2B20

AVIONICS DIAGRAM - Standard configuration

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

INDICATOR DB15
Q4E22
RED
3 1 1
Q6A22 Q6B22 YELLOW
2 2 SENDER
Q7E22N
BLACK
3 3 RIGHT

FUEL LEVEL DIAGRAM - Standard configuration

FUEL LEVEL DIAGRAM

Optional Configuration

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

3. Ground Connecting Straps

4

5
5
4 4
4

4
6

5
2
4
3 1

4
2
4
5 4

STRAP IPC REFERENCE 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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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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

CARBURETOR
VENT AND
DRAIN TUBE

Fuel System
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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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AMT 200S SECTION:1

Brake System
Page 1.19
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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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AMT 200S SECTION:1

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°

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

6.2.10 If the travel limits measured do not agree with the specified parameters,
continue the rigging procedure.

6.2.11 Move the control stick to full left; adjust the up-position of the left aileron by
regulating the up-stop screw P/N TH-5x25-RT (ref. IPC fig. 13 D item 51) on
left wing and measure the travel on the two ailerons. Compare values to the
specified travel parameters and adjust the left up-stop again if the right aileron
down-position is beyond the limits.

Note: If it is impossible to put the right aileron on the down position within
limits, stop adjusting the left up-stop screw and continue the
procedure in the right wing.

6.2.12 Move the control stick to full right; adjust the up-position of the right aileron by
regulating the up-stop screw P/N TH-5x25-RT (ref. IPC fig. 13 D item 51) on
right wing and measure the travel on the two ailerons.

6.2.13 Compare values to the specified travel parameters and adjust the right 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
Page 1.23
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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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.

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AMT 200S SECTION:1

Rudder Control
Page 1.27
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AMT 200S SECTION:1

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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August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

Trim Control System

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

Airbrake Control System

Figure 2
Page 1.31
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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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

Figure 3
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AMT 200S SECTION:1

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Page 1.33
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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

Main Landing Gear Control System

Page 1.35
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION:1

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

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August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

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

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

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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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION:1

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

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 MAINTENANCE MANUAL
AMT 200S SECTION:1

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Page 1.42
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 MAINTENANCE MANUAL
AMT 200S SECTION: 1

13. Placards
25-B

24 19
30-B

32 23 5-A

47
21-A
31
22

16 3 27 4 34 28 16
17 18 36
29

2 33
35
6 1
10
8
9

7 11

Standard version

25

24 5 19
30
22
32

31

21
21

16 3 27 4 34 28 16
17 18 36
29

35 2 33
1
6 23
10
8
9

7 11

Optional - Factory Incorporated Only

Page 1.43
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 1

25C

24
30
19

31
43
32 44
23
22
44

45 21A 5

3 27 4 34 46
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

25D

24
30-B
19

31 48
43
47
32-B
23 22
44 44

45-B 21-A 5-A 46

3 27 4 34
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

Page 1.44
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 1

25-E

24 22
30-B
19

31
32-C
-A

5-
21

23
23

21
A
5-

-A
3 27 4 34
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

25-G

24 22
30-B 38
19

31
32-E
5-
-A

A
21

23
23

A
5-
21
-A

3 27 4 34
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

Page 1.45
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 1

25G

24
30-B
19

43-A AIRFRAME TIME

31

44-A 21-A
44-A
ENGINE TIME

32-E 22
5-A 23

48-A 3 27 4 34
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

25H

24
30-B
19

31 43-A

21-A 44-A
44-A 22
3 32-E
47
23 5-A

27 4 34 48-A
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

Page 1.46
October 10, 2005 - Rev. 10 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 1

25-I

22 24
38 30-B
19

31
32-F
5-
-A

A
21

23

23

21
A
5-

-A
3 27 4 34
17 18 36
29

2 33
35 1
6
10
8
9

7 11

Optional - Factory Incorporated Only

2 5 -J

22 24
3 0 -B
19
43-A
31
3 2 -G
44-A 44-A
5-
-A

A
21

49 49
23 39 39
23

50
37 37
51
21
A
5-

3
-A

4
27 34
17 18 36
29

2 33
35 1

6
10
8

7 11

Optional - Factory Incorporated Only

Page 1.47
MM - 200-25 October 10, 2005 - Rev. 10
 MAINTENANCE MANUAL
AMT 200S SECTION: 1

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
10
8

7 11

Optional - Factory Incorporated Only

25-L
22
24
43-A
30-C

44-A 44-A
48-D
3 32-I 5-
-A

A
21

27
31 34
23
23

36
21
A
5-

-A

4 18
17
29

35

2 1 33

6
8 10

7
11

Optional - Factory Incorporated Only

Page 1.48
July 17, 2007 - Rev. 11 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

SECTION 5 - MAINTENANCE CHECKS

1. External Visual Inspection
Inspect the aircraft before every flight to prevent failures or even accidents.
1.1 External Inspection
(1) Cabin
- 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.

Página 5.1
MM - 200-25 Agosto 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

- 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
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

- Examine pedals for condition.

- Examine rudder cables for condition.
- Examine panel instruments for general condition.
- Make sure that the airbrakes retract and extend symmetrically and lock correctly.

2. Maintenance Inspection Guideline

The inspection procedures are shown on Scheduled Inspection tables. The scheduled inspections
cover the following groups:
a. operational inspection
b. control cabin
c. fuselage
d. wings
e. stabilizers
f. landing gear
g. propeller
h. power plant
i. engine test run
j. leveling and weighing
k. general

The scheduled inspections are organized as follows:

- column inspection: corresponds to the inspection or procedure you must to do;
- columm period: corresponds to the inspection period. The inspections are divided into the intervals,
as follows, first 25, 50, 100 and 200 flight hours and 1 year.
- symbol X corresponds to the inspection or operation required at the corresponding interval.

The ROTAX 912 S4 or 912 S2 engine must be overhauled every 1200 hours or 1500 hours
depending its serial number, or 10 years whichever comes first. (See ROTAX Service Bulletin n°
912-041 to select the TBO according to engine serial number).

The HOFFMANN PROPELLER HO-V62R-1/170FA must be overhauled every 1500 hours or 7

years whichever comes first. (See HOFFMANN PROPELLER Service Bulletin n° E1 to verity TBO
progression).

Only authorized workshops can adjust the engine and propeller. For more information on engine and
propeller maintenance, refer to the corresponding manuals.

Página 5.3
MM - 200-25 July 17, 2007 - Rev. 11
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
OPERATIONAL
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 X X X X

selector.

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 X X

6. Check parking brake. X X X X

7. Check gyro instruments for noise and roughness X

(if applicable).

8. Do the ignition check. X X X X

9. Check throttle for correct operation. X X X X

10. Check engine idle speed. X X X X

11. Check eletronic equipment for operation. X X X X

12. Ground ignition circuit. X X X X

13. Check flight controls, trim control and air brake for X X
freedom of movement and correct deflection.

14. Check pedals for position detents and brake operation. X X

15. Check canopy locking mechanism from inside and X X X

outside.

16. Check pilot's reports in the log book. X X X

Page 5.4
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
CONTROL CABIN
ITEM 25 50 100 200 1
h h h h year

1. Check seats, seat belts, shoulder harness and parachutes X X X

(if applicable) for condition and wear.

2. Check cabin airflow inlets. X X X

3. Check hot air ducts for leaks. Make sure the hot air valve X X X
closes correctly.

4. Check pitot and static lines for security, condition and X X

leaks.

5. Make sure that the total pressure filter is clean. X

6. Inspect panel instruments for correct attachment, X X X

markings and placards.

7. Inspect the artificial horizon, directional gyro for correct X X X

attachment and condition (if applicable).

8. Check compass correction card. X

9. Recalibrate the compass. X

10. Inspect internal illumination and instrument panel X X X

illumination (if equipped).

11. Inspect navigation lights, anti-collision lights and landing X X X

light (if installed).

12. Check fire extinguisher. X

13. Check internal placards. X X X

14. Check identification plate. X

15. Check air brakes for RETRACTED, EXTENDED and X X X

intermediate positions. Make sure that the two air brakes
move symmetrically.

NOTE: If the air brakes do not move symmetrically, contact

AEROMOT for more instructions.

Page 5.5
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
CONTROL CABIN
ITEM 25 50 100 200 1
h h h h year

16. Check cables and connections located under control X X X

column fairing.

17. Make sure there are spare fuses available. X X X

18. Check the spar attaching pin for deformation, cracks , X X X

corrosion and plays.

19. Perform instrument calibration test for the altimeter, X

speed indicator and vertical speed indicator .

Page 5.6
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
FUSELAGE
ITEM 25 50 100 200 1
h h h h year

1. Remove baggage compartment inspection panel. X X X

2. Inspect rear fuselage for condition. X X X

Also check the items, as follows:

- antennas
- cables
- rudder control
- elevator control rods
- bellcranks
- ground cables

3. Install baggage compartment inspection panel. X X X

4. Inspect external surface for deformation and cuts. X X X

5. Check canopy for cracks, deformation and sealing. X X X

6. Check canopy side locks for condition. Lubricate X X X

rails.

7. Inspect external placards. X X X

8. Check drain holes and static ports for obstruction. X X X

Clean holes and ports, if required.

9. Inspect optional equipment attaching points and X X X

supports.

Page 5.7
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
WINGS
ITEM 25 50 100 200 1
h h h h year

1. Check wing surface for condition, deformation, X X X

corrosion, wear and cracks.

2. Check lights for condition and cracks. X X X

3. Remove access panels on the outboard wings X X X

4. Inspect the pitot tube for condition and security. Make X X X

sure it is clear.

5. Remove wing/ fuselage adhesive tape. X X X

6. Make sure that flight control cables are clear in the X X X

wing folding area.

7. Inspect wing spar ends for damage. X X X

8. Check wing folding mechanism for condition, corrosion X X X

and wear. Make sure it locks correctly. Lubricate, as
necessary.

9. Check surface drain holes for condition and obstructions. X X X

10. Check ailerons for chafing, unusual noise, deformation X X X

and plays; check vent holes for condition and
obstructions

11. Inspect aileron support and bellcranks for lubrication X X X

and condition.

12. Check aileron control rods for chafing, routing and X X X

travel limits.

13. Check aileron attaching bearings for axial and radi- X X X

al plays. In case you find plays, repair as necessary.

14. Inspect wing/fuselage attachment for plays. X X X

15. Inspect wing surface near the landing gear for deformation X X X
and corrosion.

Page 5.8
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
WINGS
ITEM 25 50 100 200 1
h h h h year

16. Inspect wing fairings for cracks, corrosion and deformation. X X X

17. Operate air brakes. While extending the air brakes, inspect X X X

18. Inspect fuel tank cap gasket for deterioration. Make sure X X X
that fuel tank cap vent is clear.

19. Check fuel lines for leaks and wear. X X X

20. Drain fuel tanks. X

21. Remove fuel sump. X

22. Clean fuel strainer. X

23. Internally inspect fuel tanks for corrosion. Clean fuel X

tanks, if required.

24. Install new adhesive tape. X X X

25. Install access panels. X X X

Page 5.9
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
STABILIZER (HORIZ. AND VERT.)
ITEM 25 50 100 200 1
h h h h year

01. Remove access panel on vertical stabilizer X X X

02. Inspect surfaces for deformation, wear and cracks. X X X

03. Check elevator vent holes for condition and bstruction. X X X

04. Check flight control travel limits and deflections. X

05. Check lights for condition, security and cracks. X X X

06. Check horizontal stabilizer for plays and correct X X X

torque of the attaching screw .

07. Lubricate elevator and rudder rod ends. X X X

08. Check elevator control rod for chafing, routing and X X X

travel.

09. Check elevator trim for chafing, freedom of X X X

movement and travel. Compare the positions of the
surface and the indicator.

10. Check vertical stabilizer supports and bearings for X X X

corrosion.

11. Check rudder attach points; check rudder vent hole X X X

12 Check rudder attaching nut for correct torque. X X X

13. Use a 10x glass to inspect rudder axles and spherical X X

bearings for deformation, cracks, wear and plays.

14. Check rudder control cables and nicopress sleeves. X X X

15. Install access panel. X X X

16. Make sure that total energy tube is clear. if in use. X X X

Page 5.10
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
LANDING GEAR
ITEM 25 50 100 200 1
h h h h year
01. Put aircraft on jacks. X X X

02. Put an assistant in the control cabin. Ask this person to X X X

extend and retract the landing gear while you make sure
that the wheels fit correctly into the wheel well. The covers
must also close correctly.

NOTE: If the landing gear legs do not retract symmetrically,

there is a malfunction on the angular gear box and you
must contact AEROMOT for more instruction.

03. Remove the central console and make sure that the X X X
landing gear control handle fits correctly in the EXTENDED
and RETRACTED positions.

04. Inspect landing gear uplock microswitch and air brakes X X X

warning microswitch

05. Inspect downlock microswitch. X X X

06. Check landing gear warning system. X X X

07. Check shock struts for corrosion, correct travel and X X X

leakage.

CAUTION: In case of leakage, disassemble shock strut

using the tool P/N 35350-A-23 because of the compressed
internal spring and replace oil leaking o'rings.

08. Inspect landing gear legs, torque links, drag brace and X X X
downlock for corrosion, cracks and proper attachment.

09. Calibrate shock struts, if required. X X X

10. Inspect tires for wear, cuts, pressure leakage and X X X

slippage.

11. Remove the wheels and inspect the sealed bearings for X X
wear.

CAUTION: Do not put and clean the sealed bearings into

hydrocarbon solvents.

Page 5.11
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
LANDING GEAR
ITEM 25 50 100 200 1
h h h h year

12. Inspect wheels for cracks using a 10x glass. X X X

NOTE: In case of hard landing or 500 flight hours, inspect

wheels with penetrant.

13. Inspect brake linings and discs for wear, distortion and X X X
deformation.

14. Check brake fluid level. X X X

15. Inspect brake hoses for leaks, condition and security. X X X

16. Remove tail wheel and check it and the strut for condition, X
security and free movement.

16. Inspect tail wheel springs. X X X

17. Lubricate tail wheel. X X X

18. Remove aircraft from jacks. X X X

Page 5.12
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
PROPELLER
ITEM 25 50 100 200 1
h h h h year

01. Remove spinner X X

02. Inspect spinner and plate for cracks, deformation X X

and attaching hole wear.

03. Inspect propeller attaching nuts. Torque the nuts to X X

390-410 in.lb. and apply the torque seal.

04. Use a magnifying glass to check propeller blades X X

for vibration spots, wear and cracks. Repair the
propeller according to the Propeller Manual ( if
required).

05. Check for smooth turning of the blades. X X

06. Slightly grease the four pitch change rods of the X X

outside pitch change mechanism where they slide into
the bushings.

07. Clean and grease thrust plate slightly. X X X

08. Check visible hub parts for cracks and corrosion. X X

09. Check screws and lockwires. X X

10. Check counterweights for correct position. X X

11. Make sure that the metal ferrule is correctly sealed X X

with silicone rubber material.

12. Check pitch change cable for condition. X X

13. Install spinner X X

NOTE: Overhaul the propeller every 1500 flight hours or 7

years whichever comes first.

Page 5.13
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
POWER PLANT
ITEM 25 50 100 200 1
h h h h year

01. Remove engine cowling. X X X X

02. Inspect frame 1 and firewall for deformation, cracks, X X X

corrosion and security.

03. Check battery gravity and electrolyte level. X X X

04. Clean battery terminals and check electrical wires. X X X

05. Remove battery. X X X

06. Check battery box for acid leakage. Make sure that X X X
batterybox drain is clear.

07. Make sure that the cell filler caps close correctly. X X X

08. Inspect the electrical box. X X X

09. Check electrical wiring, fuses, relays and capacitor for X X X

wear and interference.

10. Inspect alternator connectors for security and X X X

corrosion.

11. Check power plant cables for condition and X X X

security.

12. Inspect starter for condition and corrosion. X X X

13. Inspect the engine for damage and abnormalities. X X X X

14. Inspect cooling air ducts, baffling and cylinder cooling fins X X X X
for obstructions, cracks, wear and condition. Take note of
temperature influence.

15. Inspect temperatures and pressure sensors for security X X X X

and condition.

16. Inspect all coolant hoses for damage, leak, hardening from X X X X
heat, porosity, loose connections and secure attachments.
Verify routing for kinks and restricted elbows.

17. Inspect the leakage bore at the base of the water pump for X X X X
signs of leakage.

Page 5.14
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
POWER PLANT
ITEM 25 50 100 200 1
h h h h year

18. Inspect the expansion tank for X X X X

damage and abnormalities. Verify coolant level, fill as
necessary. Check radiator cap. Inspect rubber plate on
expansion tank base for secure fit.

19. Inspect and clean the low level sensor of expansion tank X

20. Inspect the overflow bottle for damage and X X X X

abnormalities.Verify coolant level, replenish as necessary.
Check line from expansion tank to overflow bottle for
damage, leakage and clear passage.
Verify venting bore in cap of overflow bottle for clear
passage.

21. Inspect all oil hoses for damage, leak, hardening from X X X X
heat, porosity, security of connections and attachments.
Verify routing for kinks or restricted elbows.
NOTE: Hose service life is 5 years.

22. Inspect all fuel hoses for damage, leakage, hardening X X X X

from heat, porosity, secure connections and attachments.
Verify routing for kinks or restricted elbows.
NOTE: Hose service life is 5 years.

23. Inspect engine mounts and fasteners for secure fit, X X X X

damage from heat, cracks and deformation.

24. Check attachment screws and nuts of all external parts X X X X

for security and fit. Check safety wiring, renew as
necessary.

25. Check the backlash. X

26. Check the friction torque. Record Actual Friction Torque X

See Rotax Maintenance Manual

27. Remove oil drain screw from oil tank. X X X

Drain old oil and dispose as per environmental regulations.

28. Remove oil filter from engine and install new oil X X X
filter.Lubricate mating sealing ring of new oil filter with
engine oil. Screw on new filter by hand.

29. Cut oil filter housing without producing any metal chips X X
and inspect filter mat.

Page 5.15
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
POWER PLANT
ITEM 25 50 100 200 1
h h h h year

30. Renew gasket ring of drain screw on oil tank.Fit drain X X X

screw and tighten to 25 Nm (220 in.lbs.).

31. Refill oil tank with approx. 3 litres of oil. X X X X

For oil quality refer to Operator's Manual and Service
Information ROTAX SI-912-016 / SI-914-019.

32. Flush the coolant system. X X X

33. Inspect the air filter. X

34. Do the carburetor synchronization check. Mechanical or X X

pneumatic synchronization.

35. Checkthe float chamber venting. Check venting lines for X X

condition, secure attachment, clear passage and routing
for kinks and restrictions.

36. Check free movement of the carburetor activation (throttle X X X

lever and starting carb).

37. Remove and install the carburetors in the course of X

carburetor verification.

38. Inspect the carburetor sockets for damage abnormalities, X

cracks, wear condition and unserviceabilities.Take note
of temperature influence.

39. Remove all spark plugs. Check caloric value and clean the X X X
spark plugs.

40. Check electrode gap and adjust as necessary. Renew as X X

required.

41. Renew spark plugs. X

ATTENTION:
Apply heat conduction compound on
spark plug thread.

42. Check spark plug connectors for security. X X X

Minimum pull-off force is 30 N (7 lb).

43. Check compression by differential pressure method. X

Page 5.16
July 17, 2007 - Rev. 11 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
POWER PLANT
ITEM 25 50 100 200 1
h h h h year

44. Check the exhaust system for corrosion, burns, cracks, X X X

leaks and security.

45. Remove the exhaust tube thermal insulator and inspect it X

for cracks, leaks and distortion. Repair or replace it, as
necessary.

46. Make sure that the exhaust system is at the correct X

distance from the engine mount or lower cowling.

47. Clean the engine. Do not use easily imflammable engine, X X X

caustic cleaning agents or a high pressure cleaner. Refer
to the Rotax Maintenance Manual for more instructions.

Page 5.17
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
ENGINE TEST RUN
ITEM 25 50 100 200 1
h h h h year

01. Start the engine and run to operating temperature. X X X

02. Check ignition circuits at 4000 rpm engine speed. X X X

03. Check carburetor preheating. X X X

04. After engine test run, re-tighten the oil filter by hand. X X X

Page 5.18
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
LEVELING AND WEIGHING
ITEM 25 50 100 200 1
h h h h year

1. Perform weight and balance procedure at the end of X

the inspection, if necessary.

NOTE: If aircraft basic weight is changed due to repair

or paint, perform weight and balance procedure after the
inspection.

Page 5.19
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

FIRST EVERY
GENERAL
ITEM 25 50 100 200 1
h h h h year

01. Make sure that the airplane is clean. X X X

02. Check the aircraft is in accordance with Federal X X X

Regulation Authority specifications.

03. Check that all applicable Service Bulletins and X X X

Airworthiness Directives have been properly applied.

04. Check that Flight Manual is on board. X X X

05. Check that aircraft papers are updated and log X X X

books (airframe, propeller and engine) are correctly
completed.

Page 5.20
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

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
MM - 200-25 July 17, 2007 - Rev. 11
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

CLIMATIC
ºC ºF MULTI-GRADE OILS
CONDITIONS

40 100

TROPICAL 30

SAE 20W-50
SAE 20W-40
80

SAE 15W-50
SAE 15W-40

SAE 5W-50
SAE 5W-40
20

SAE 10W-40
60

10

TEMPERATE 40

20
-10

0
-20
ARCTIC
-30 -20

Lubrication chart

ATTENTION:

THE AMBIENT GROUND AIR TEMPERATURES LISTED IN THE CHART ABOVE ARE MEANT
ONLY AS A GUIDE SPECIFIED BY THE ENGINE MANUFACTURER AND AN INDICATION THAT
A HIGHER VISCOSITY OIL SHOULD BE CONSIDERED WHEN THE OIL INLET TEMPERATURE
APPROACHES THE MAXIMUM DURING OPERATION.

3.4 Engine Coolant

- Conventional coolant with 50% water content. See recomended coolant with a mixture
of 50% antifreeze and 50 water in ROTAX SI-912-016 / SI-914-019.

Page 5.22
July 17, 2007 - Rev. 11 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

4. Recommended Calibration Pressure

4.1 Main Gear Tires

Recommended pressure : 45 ± 1.5 psi (3.2 ± 0.1 Kg/ cm2))

4.2 Tail Gear Tire

Recommended pressure : 36.2 ± 1,5 psi (2.5 ± 0,1kg/cm2)

5. Battery

The battery GILL G-35 has the following characteristics :

12 V / 35 AH

In case you need to recharge the battery, clean the terminals first.

Do not let the current or the voltage reach more than 1,4 A and 12 V, respectively. Examine
electrolyte level frequently. Maintain the level between 0.15 in and 0.30 in above the positive and
negative plates. If the level is low, fill it with destilled water.

In case of electrical system malfunction, refer to the electrical system diagram on Section 1.

6. General Maintenance

6.1 Fatigue

Fatigue mainly happens on rods, levers, mounts, mufflers, brackets and exhaust tubes because
of high rates of vibration or high loads. Examine these parts carefully, specially their openings,
angles, welding points and joints. You can identify fatigue by means of visible cracks but you can
also use magnifying glass, penetrant or magnaflux. If you find a crack on a part not so important,
drill a stop hole of 0.06 or 0.09 inches (2 or 3 mm) of diameter. If you find a crack on an important
part, remove the part and replace it.

6.2 Erosion, Scratches and Nicks

Erosion starts on wing leading edges and propeller blades.

For propeller blades, refer to the Propeller Manual.
For wings and composite material parts, refer to Section 4.

Page 5.23
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 5

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.

Page 5.24
August 10, 2004 - Rev. 8 MM - 200-25
 MAINTENANCE MANUAL
AMT 200S SECTION: 6

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
MM - 200-25 August 10, 2004 - Rev. 8
 MAINTENANCE MANUAL
AMT 200S SECTION: 6

4. Jacking
CAUTION

BEFORE YOU PUT THE AIRCRAFT ON JACKS, TIE ONE

COUNTERWEIGHT TO THE TAIL TO PREVENT THE AIRCRAFT FROM
OVERTURNING.

Use the jack points located on the lower wing surface near the landing gear to put the aircraft on
jacks.

5. Technical Documentation

The following manuals are delivered with each aircraft:

Flight Manual - P/N 200-24

Maintenance Manual - P/N 200-25
Parts Catalog - P/N 200-26
Operator's Manual for all versions of Rotax 912 - P/N 899.371
Maintenance Manual for Rotax Engine Type 912 Serie - P/N 899.372
Owner's Manual for Hoffmann Propeller HO-V62R-1/170 FA - P/N E 0107.72

Page 6.2
July 17, 2007 - Rev. 11 MM - 200-25