AEROMOT AMT 200S SUPER XIMANGO S, Maintenance Manual

Page 1: ...200 25 MAINTENANCE MANUAL AMT 200S...

Page 2: ...ace area 201 29 Sqft 18 70 m2 Dihedral 2 30 Profile Naca 643 618 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...

Page 3: ...l 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...

Page 4: ...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 Thecanopycanbejetti...

Page 5: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 1 12 Air Pressure Ports 1 Dynamic air pressure port 2 Static air pressure port 3 Totalenergy Page 1 4 August 10 2004 Rev 8...

Page 6: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Page 1 5 August 10 2004 Rev 8 1 13 Vent holes and drains...

Page 7: ...PP3A4N AIRCRAFT END PP3B10N PP2A4N PP1D10 K1 SHUNT PP1A4 ENGINE RELAY 20A SOARING BUS BAR PP18A22 PP17A22 2A 2A 30A CHT 1 1 MAIN BUS BAR AM METER CHT 5 5 8 8 4 4 BATTERY PP5A10 MAIN SOARING PP8A20N A...

Page 8: ...N 2A BLACK RED PP18A22 PP17A22 CHT PP4A10 MAIN BUS 30A AMMETER CHT 4 8 5 1 HOUR METER 2A FUSE LINE MAIN BUS BAR SWITCH OIL PRESSURE E8A22 E7A22 E6A22 BATTERY SHUNT K1 2A E9A22 E10A22 HOUR METER 2A 10A...

Page 9: ...200 127 G G B C R 25V 22 000 uf ALTERNATOR E7A22 KK3A20 30A ALTERNATOR HOUR METER MAIN BUS BAR PP11A20 K4 MAGNETO B MAGNETO A KK3A20 JK4A18 JK3A18 PP1A4 BATTERY KK1A4 K3 IGNITION B IGNITION A JK2A18 J...

Page 10: ...K4 ALTERNATOR ALTERNATOR DIAGRAM Motorglider s n 200 128 and on FLIGHT INSTRUMENT DIAGRAM Motorgliderss n200 119 200 122to200 132 F7A22 F14A22 F1A22 DIREC GYRO F8A22 ATT INDICATOR F13A22 F2A22 TURN BA...

Page 11: ...OPTIONAL F13A22 F2A22 TURN BANK OPTIONAL 2A ATT 2A GD T B 2A MAIN BUS BAR F3A22N PILOT F12A22N COPILOT TURN BANK OPTIONAL F11A22 F10A22 2A T B DIREC GYRO OPTIONAL F4A22 F3A22 2A GD F6A22N PILOT F15A22...

Page 12: ...22 3 3 2 2 1 1 CONNECTOR 6 4 5 RIGHT WING GW1A22 AIR BRAKE MICRO SWITCH NC C NO GW6A22 GW2B22N GW2A22N GW2C22N MICRO SWITCH NC NO C GW5A22 GW4A22 GEAR UP GW5D22 GW12A22 GW1B22 GEAR LIGHT 2A GW1B22 GW3...

Page 13: ...G GW1A22 AIR BRAKE MICRO SWITCH NC C NO GW6A22 GW2B22N GW2A22N GW2C22N MICRO SWITCH NC NO C GW5A22 GW4A22 GEAR UP GW5D22 GW12A22 GW1B22 GEAR LIGHT 2A GW1B22 GW3B22 GW4B22 RIGHT GEAR LEFT GEAR DOWN DOW...

Page 14: ...R GND BATTERY MAIN BUS E8A22N E2A22 E3A22 E1A22 E4A22N 2A 5A RV1A18 RV1A18 2A F5A22 2A F3A22 2A F1A22 3A SN1A20 2A ALTITUDE ENCODER TRANSPONDER VHF COMM ATT INDICATOR OPTIONAL INTERCOM OPTIONAL TURN A...

Page 15: ...L LEVEL INDICATOR 2A FUEL INDICATOR 3 5 1 1 2 3 1 2 3 RED YELLOW BLACK RED YELLOW BLACK SENDER RIGHT SENDER LEFT 1 2 3 1 2 3 5A PM2B20 PM2B20N PM1A20 PM2A20N AUX POWER LEFT AUX POWER RIGHT AUX POWER 5...

Page 16: ...2 6 3 4 2 6 2 5 4 5 4 4 3 Ground Connecting Straps Ground Connecting Straps Table STRAP 1 2 3 4 5 6 IPCREFERENCE IPCFIGURE05 IPCFIGURE13 IPCFIGURE15 IPCFIGURE16 IPCFIGURE18 IPCFIGURE20 PAGE 2 16 2 44...

Page 17: ...systemcomponentsbelow 1 Tank cap and vent breather 2 Drainvalves 3 Left fuel tank 11 89 U S gallons 45 liters 4 Right fuel tank11 89 U S gallons 45 liters 5 Fueltubesandconnections 6 Electric fuel pum...

Page 18: ...AINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 FuelSystem Page 1 17 August 10 2004 Rev 8 CARBURETOR VENT AND DRAIN TUBE FIREWALL FUEL RETURNING LINE TO FUEL TANKS 3 2 2 4 6 10 9 8 7 5 7 5 5 5 5 5 5 5 5...

Page 19: ...oshell 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 th...

Page 20: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Brake System Page 1 19 August 10 2004 Rev 8...

Page 21: ...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 o...

Page 22: ...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 Movethecontrolsticktofullright measurethetravelonthetwoaileronsa...

Page 23: ...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...

Page 24: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 AileronControls Page 1 23 August 10 2004 Rev 8...

Page 25: ...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 hor...

Page 26: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 ElevatorControl Page 1 25 August 10 2004 Rev 8...

Page 27: ...s 2 Controlcables 3 Rudderbellcrank 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...

Page 28: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 RudderControl Page 1 27 August 10 2004 Rev 8...

Page 29: ...atthehorizontalstabilizertolocktheelevatorintheneutral 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 indi...

Page 30: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 TrimControlSystem Page 1 29 August 10 2004 Rev 8...

Page 31: ...acted Inspecttheairbrakelockinganditsopeningbyadjustingthelength ofthepushrod fig 2item4 locatedintheairbrake Theairbrake heightmustbethesameforthetwowingsandtheairbrakesmust opensimultaneously Measur...

Page 32: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Airbrake Control System Figure 2 Page 1 31 August 10 2004 Rev 8...

Page 33: ...ANCEMANUAL AMT 200S SECTION 1 MM 200 25 Figure 3 1 Airbrake control lever 2 Centerconsole 3 Airbrake control link rod 4 Stop screw 5 Airbrake micro switch Page 1 32 August 10 2004 Rev 8 Figure 2 6 38...

Page 34: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Thispageintentionallyleftblank Page 1 33 August 10 2004 Rev 8...

Page 35: ...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 Controlarm 7 Rod 8 La...

Page 36: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Main Landing Gear Control System Page 1 35 August 10 2004 Rev 8...

Page 37: ...t 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 abo...

Page 38: ...NTAIN THE LANDING GEAR EXTENDED BY MEANS OF THE FORK BECAUSE THE COMPENSATION SPRING CAN INADVERTENTLY CLOSE THE GEAR 2 Turnthestopscrew detailsitem6 2 5turnsclockwiseandlockitwiththelocknut to obtain...

Page 39: ...ol link rod 2 so it does not pass the upper dead centerasitisshowninthefigurebelow formingatmaximumanangleof175 between the rodand the torque tube cranck 2 Tighten the nut of the control link rod and...

Page 40: ...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 t...

Page 41: ...he 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 dro...

Page 42: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Page 1 41 November 23 2004 Rev 9 ln order to identify the main subassemblies of the motorglider AMT 200S Super Ximango refer to the table below...

Page 43: ...MAINTENANCEMANUAL AMT 200S SECTION 1 MM 200 25 Thispageintentionallyleftblank Page 1 42 August 10 2004 Rev 8...

Page 44: ...andard version Optional FactoryIncorporatedOnly 29 35 17 27 4 2 16 34 36 28 16 3 25 19 18 24 5 32 30 31 1 33 6 7 10 9 8 23 11 21 2 1 22 29 35 17 27 4 2 16 34 36 28 16 3 25 B 19 5 A 21 A 23 22 18 24 32...

Page 45: ...atedOnly 29 35 17 4 2 36 34 44 46 3 25C 19 27 32 43 44 45 18 21A 24 23 31 30 5 22 1 33 6 7 10 9 8 11 Optional FactoryIncorporatedOnly 29 35 17 4 2 36 34 44 47 46 3 25D 19 27 32 B 43 44 45 B 18 21 A 24...

Page 46: ...edOnly Optional FactoryIncorporatedOnly 34 3 19 27 31 30 B 22 32 E 25 G 38 24 29 35 17 4 2 36 18 1 33 6 7 10 9 8 11 2 1 A 2 1 A 23 2 3 5 A 5 A 34 3 19 27 31 30 B 22 32 C 25 E 24 29 35 17 4 2 36 18 1 3...

Page 47: ...A 44 A 43 A 25G 19 27 32 E 5 A 24 23 31 30 B 21 A 22 29 35 17 4 2 36 18 1 33 6 7 10 9 8 11 AIR FRAMETIME ENGIN E TIME Optional FactoryIncorporatedOnly 29 35 17 4 2 36 18 1 33 6 7 10 9 8 11 3 3 7 2 4 A...

Page 48: ...39 37 37 44 A 44 A 43 A 2 7 2 9 3 5 1 7 4 2 3 6 1 8 1 3 3 6 7 1 1 0 1 9 8 2 1 A 2 1 A 23 2 3 5 A 5 A 19 3 1 3 0 B 2 2 3 2 G 2 5 J 2 4 Optional FactoryIncorporatedOnly 34 3 27 29 35 17 4 2 36 18 1 33 6...

Page 49: ...Optional FactoryIncorporatedOnly 3 4 3 27 2 9 35 1 7 4 2 3 6 1 8 1 3 3 6 7 1 1 0 1 9 8 19 22 32 H 25 K 30 B 38 2 4 21 A 23 5 A Optional FactoryIncorporatedOnly 29 35 17 4 2 18 1 33 6 7 10 11 9 8 24 2...

Page 50: ...dom of movement and plays Examinethewingfoldingmechanismforgeneralcondition playsandfairingattachingpoints Examine wingtip for condition Examine tire for proper inflation cust and slippage Examine lea...

Page 51: ...levator 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...

Page 52: ...tion corresponds to the inspection or procedure you must to do colummperiod correspondstotheinspectionperiod Theinspectionsaredividedintotheintervals as follows first 25 50 100 and 200 flight hours an...

Page 53: ...k selector Checkfuelquantityandrecalibratefuelsystem ifnecessary Check alternator output Check carburetor heat air control Check parking brake Check gyro instruments for noise and roughness ifapplicab...

Page 54: ...nd placards Inspect theartificial horizon directional gyro for correct attachment and condition if applicable Check compass correction card Recalibrate the compass Inspect internal illumination and in...

Page 55: ...connections located under control columnfairing Make sure there are spare fuses available Check the spar attaching pin for deformation cracks corrosion and plays Perform instrument calibration test f...

Page 56: ...les Install baggage compartment inspection panel Inspect external surface for deformation and cuts Check canopy for cracks deformation and sealing Check canopy side locks for condition Lubricate rails...

Page 57: ...wear Make sure it locks correctly Lubricate as necessary Checksurfacedrainholesforconditionandobstructions Check ailerons for chafing unusual noise deformation and plays check vent holes for condition...

Page 58: ...ect fuel tank cap gasket for deterioration Makesure that fuel tank cap vent is clear Check fuel lines for leaks and wear Drain fuel tanks Remove fuel sump Clean fuel strainer Internally inspect fuel t...

Page 59: ...d for chafing routing and travel Check elevator trim for chafing freedom of movement and travel Compare the positions of the surface and the indicator Check vertical stabilizer supports and bearings f...

Page 60: ...landing gear uplock microswitch and air brakes warning microswitch Inspect downlock microswitch Check landing gear warning system Check shock struts for corrosion correct travel and leakage CAUTION In...

Page 61: ...fhardlandingor 500flighthours inspect wheelswithpenetrant Inspect brake linings and discs for wear distortion and deformation Check brake fluid level Inspect brake hoses for leaks condition and securi...

Page 62: ...r smooth turning of the blades Slightly grease the four pitch change rods of the outside pitch change mechanism where they slide into the bushings Clean and grease thrust plate slightly Check visible...

Page 63: ...security and corrosion Check power plant cables for condition and security Inspect starter for condition and corrosion Inspect the engine for damage and abnormalities Inspectcoolingairducts bafflingan...

Page 64: ...5 years Inspect all fuel hoses for damage leakage hardening fromheat porosity secureconnectionsandattachments Verify routing for kinks or restricted elbows NOTE Hose service life is 5 years Inspect e...

Page 65: ...on secureattachment clearpassageandrouting for kinks and restrictions Checkfreemovementofthecarburetoractivation throttle lever and starting carb Remove and install the carburetors in the course of ca...

Page 66: ...austtubethermalinsulatorandinspectit for cracks leaks and distortion Repair or replace it as necessary Make sure that the exhaust system is at the correct distance from the engine mount or lower cowli...

Page 67: ...year MM 200 25 Start the engine and run to operating temperature Check ignition circuits at 4000 rpm engine speed Checkcarburetorpreheating After engine test run re tighten the oil filter by hand X X...

Page 68: ...h h year MM 200 25 LEVELINGANDWEIGHING 1 Perform weight and balance procedure at the end of the inspection if necessary NOTE If aircraft basic weight is changed due to repair or paint perform weight a...

Page 69: ...Federal Regulation Authority specifications Check that all applicable Service Bulletins and Airworthiness Directives have been properly applied Check that Flight Manual is on board Check that aircraft...

Page 70: ...ove 32 F or 145 psi 10 19 kg cm2 at temperatures below 32 F 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...

Page 71: ...NSIDEREDWHENTHEOILINLETTEMPERATURE APPROACHESTHEMAXIMUMDURINGOPERATION 3 4 Engine Coolant Conventionalcoolantwith50 watercontent Seerecomendedcoolantwithamixture of 50 antifreeze and 50 water in ROTAX...

Page 72: ...e of electrical system malfunction refer to the electrical system diagram on Section 1 6 General Maintenance 6 1 Fatigue Fatiguemainlyhappensonrods levers mounts mufflers bracketsandexhausttubesbecaus...

Page 73: ...rnal 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...

Page 74: ...ntalstabilizerbolt 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...

Page 75: ...earthelandinggeartoputtheaircrafton 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...