Page 1 Changed 3 Maintenance Manual July 1 2008...
Page 2 Changed 3 List of Effective Pages Insert latest changed pages. Destroy superseded pages. Note: Changed pages are indicated by the marking “changed” at the top of the page. Dates of issue for original and changed pages are: Original….. 0….. September 1 2005 Changed…...
Page 3 Changed 1 Table of Contents Section Page General Description……………………………………………… Ground Handling, Servicing, Cleaning, Lubrication and Inspection……………………………………… Structures – Fuselage…………………………………………… Structures – Wings and Empennage………………………….. Structures – Landing Gear and Brakes……………………….. Structures – Aileron Control System…………………………... Structures – Wing Flap Control System………………………. Structures –...
Page 4 “Level of Maintenance” and the minimum level of certification needed to accomplish the task “Certification Required”. The REMOS G-3 /600 complies to the rules of the Light Sport Aircraft airworthiness standards and does not conform to standard category airworthiness requirements.
Page 5 Changed 1 Common conversions and abbreviations Unit of length 1 mm = 0.03937 in 1 in = 25.4 mm 1 ft = 0.3048 m Unit of area 1 cm = 0.155 sq in 1 sq in = 6.4516 cm Unit of volume 1 cm = 0.06102 cu in 1 cu in = 16.3871 cm...
Page 6 1-10 Aircraft Description REMOS G-3 Series aircraft, described in this manual, are highwing monoplanes of all composite monocoque construction. These aircraft are equipped with a fixed tricycle landing gear. All models are equipped with composite (glass fiber) main landing gear struts including wheel fairings and a steerable nose gear.
Page 7 Changed 1 Figure 1-1. Gross Weight……………………………………………….. 1320 lb Fuel Capacity………………………….……………………. 21 gal. Oil Capacity…………………………………………………. 0.75 gal. Engine Model (Refer to Section 11 for Engine Data)…… Rotax 912 Series Propeller (Fixed Pitch)……………………………………… 66.7" Tonini GT Main Wheel Tires…………………………………………… 6.00 x 4, 6-Ply Rating Pressure……………………………………………...
Page 8 Changed 1 Caution DO NOT REUSE SELF-LOCKING NUTS. Tire Inflation Pressure Maintain tire pressure at the air pressure specified in figure 1-1. When checking tire pressure, examine tires for wear, cuts, bruises and spillage. Remove oil, grease and mud from tires with soap and water. Approved Oils and Capacities In general we recommend referring to the latest ROTAX 912 Series engine operator's manual to check for a suitable engine oil.
Page 9 Changed 1 Table of lubricants Since the temperature range of neighboring SAE grades overlap, there is no need for change of oil viscosity for a short duration of ambient temperature fluctuation. Climatic conditions Multi-grade oils Tropical…………………………………… SAE 20W-50, SAE 20W-40 SAE 15W-50, SAE 15W-40 SAE 10W-40 SAE 5W-50, SAE 5W-40...
Page 10 Changed 1 Max. negative "g" for 5 seconds…………………… -0.5 g - 0.5 g Oil Pressure Max. for short period at cold start………………… 100 psi 100 psi Min. (below 3500 rpm)…………………………….. 12 psi 12 psi Normal (above 3500 rpm)………………………… 29 - 73 psi 29 - 73 psi Deviation from Bank Angle max………………………….
Page 11 Changed 1 Weight and Balance Information To perform a successful weight and balance calculation, the center of gravity "C.G." has to be determined with all installed equipment, including engine oil, cooling liquid, but without fuel. Figure 1-6. shows how to conduct the C.G. determination. All measurements including a listing of all installed equipment have to be noted in the separate weight and balance calculation form (an example is given in figure 1-7.).
Page 12 Changed 1 Figure 1-6. Figure 1-7. Section 1-7...
Page 13 1-8. When damage is determined to any part of the aircraft please contact your REMOS distributor when in doubt about replacement or repair. No repairs must be done to any of the listed parts due to flight safety! Figure 1-9.
Page 14 Changed 1 Engine Mount Screws Engine Shock Mounts Throttle Control Cables Other specific Engine Components………… Refer to ROTAX Engine Maintenance Manual. Propeller………………………………………. Refer to TONINI Operators Manual Landing Gear…………………………………. Tires and Tubes Cotter Pins in General Hydraulic Line Fittings Self Locking Nuts in General Brake Pads Brake Discs All Wheel and Landing Gear...
Page 15 (refer to Section 2). If in doubt about the airworthiness of the aircraft, it is strongly recommended to contact your REMOS distributor. The aircraft must not be flown unless concerns about flight safety are cleared completely.
Page 16 Section 2 Ground Handling, Servicing, Cleaning, Lubrication and Inspection Table of Contents Page Ground Handling……………………………………………………… 2.1.1 Towing…………………………………………………………. 2.1.2 Hoisting………………………………………………………… 2.1.3 Jacking…………………………………………………………. 2.1.4 Parking…………………………………………………………. 2.1.5 Tie-Down………………………………………………………. 2.1.6 Flyable Storage……………………………………………….. 2.1.6.1 Returning Aircraft to Service………………………… 2.1.7 Temporary Storage…………………………………………… 2.1.7.1 Inspection During Storage…………………………… 2.1.7.2 Returning Aircraft to Service…………………………...
Page 17 2.1.2 Hoisting The aircraft may be lifted with a hoist of at least 1000 lb (0.5 tons) capacity by using suitable slings. To apply the slings, the wings have to be folded back first (refer to Pilot Operating Handbook, chapter 8). Now the wing main bolt brackets at the fuselage are accessible.
Page 18 During the 30 day non-operational storage or the first 20 hours of intermittent engine operation, every seventh day the propeller shall be rotated through 10 revolutions, without running the engine. If the aircraft is stored outside, tie-down in accordance with paragraph 2.1.5. In addition, the pitot tube, static airvents, air vents, openings in the engine cowling, and or similar openings shall have protective covers installed to prevent entry of foreign material.
Page 19 Check tires for proper inflation. Check battery and install. Check the oil sump has proper quantity of engine oil (Refer to Pilot Operating Handbook and/or Rotax Operator´s Manual for instructions). Service induction air filter and remove warning placard from propeller. Remove materials used to cover openings.
Page 20 2.2.4 Engine Induction Air Filter The induction air filter keeps dust and dirt from entering the induction system. The value of maintaining the air filter in a good clean condition can never be overstressed. More engine wear is caused through the use of dirty or damaged air filter than is generally believed.
Page 21 Figure 2-1. 2.2.6 Tires Maintain tire pressure at the air pressure specified in figure 1-1. When checking tire pressure, examine tires for wear, cuts, bruises and spillage. Remove oil, grease and mud from tires with soap and water. Note Recommended tire pressures should be maintained. Especially in cold weather, remember that any drop in temperature of the air inside a tire causes a corresponding drop in air pressure.
Page 22 Figure 2-2 Section 2-7...
Page 23 Figure 2-2. Daily Fuel Tank Filler Service after each flight. Keep full to retard condensation. Refer to paragraph 2.2.1. Fuel Tank Sump Drain Drain off any water and sediment before first flight of the day. Pitot and Static Ports Check for obstructions before first flight of the day. Induction Air Filter Inspect and service under dusty conditions.
Page 24 Fuel Tank Sump Drain Drain off any water and sediment, refer to paragraph 2.2.2 for details. 2.2.7 Hydraulic Brake System Check brake master cylinder and refill with correct grade of brake fluid. To refill, DOT 4 automobile brake fluid is required, as specified in the inspection chart, and no aircraft hydraulic fluid must ever be used! Bleed the brake system to remove entrapped air whenever there is a spongy response to the brake lever.
Page 25 2.3.3 Painted Surfaces The painted exterior surfaces of the aircraft, under normal conditions, require a minimum of polishing and buffing. Approximately two weeks are required for acrylic paint to cure completely; in most cases, the curing period will have been completed prior to delivery of the aircraft.
Page 26 2.3.7 Propeller Wash hub and blades with a soft cloth and suitable cleaning solvent, then dry thoroughly with compressed air. Caution Do not use gasoline, alcohol, benzene, acetone, or laquer thinner. These solvents will soften and damage the laquer finish. 2.3.8 Wheels The wheels should be washed periodically and examined for corrosion, cracks and dents in the wheel halves or hubs.
Page 27 100 hours and 200 hours. To conduct these inspections it is mandatory to use the factory inspection form (REMOS Checklist-B Service/Maintenance) latest issue. When conducting the after sales 20 hour inspection, all items marked as 20 hour service would be inspected, serviced or otherwise accomplished as necessary to insure continued airworthiness.
Page 28 Pilot Operating Handbook. During run-up, observe the following, making note of any discrepancies or abnormalities. We recommend to use the "static-test-report form" included in the REMOS Checklist-B Service/Maintenance form for documentation: Engine temperatures and pressures.
Page 29 Read all inspection requirements paragraphs prior to using these charts. These charts may only be used accompanied by the special factory inspection form: REMOS Checklist-B Service/Maintenance. A FAR-43 related inspection form (annual/100hr. inspection) is attached to this maintenance manual. Service / hours S.i.i.
Page 30 Service / hours S.i.i. 20 100 200 Fuel System Fuel drain valve Fuel tank vent, cap and placards Fuel tank sump drains Drain fuel and check outlet screen Fuel shut-off valve and placards Service / hours S.i.i. 20 100 200 Landing Gear Main gear wheels and fairings Nose gear wheel and fairing Wheel bearings...
Page 31 Service / hours S.i.i. 20 100 200 Control Systems In addition to the items listed below, always check for correct direction of movement, correct travel and correct cable tension. Cables, terminals, pulleys, pulley brackets, cable guards, rods and rod connections, linkage bearings Trim control switch, indicator Travel stops Flap control switch, indicator...
Page 32 Section 3 Structures - Fuselage Table of Contents Page Windshield and Windows……………………………………………. 3.1.1 Description…………………………………………………….. 3.1.2 Cleaning……………………………………………………….. 3.1.3 Waxing…………………………………………………………. 3.1.4 Repairs…………………………………………………………. 3.1.4.1 Scratches………………………………………………. 3.1.4.2 Cracks………………………………………………….. 3.1.5 Replacement…………………………………………..... 3.1.5.1 Removal………………………………………..... 3.1.5.2 Installation……………………………………………… Cabin Doors…………………………………………………………… 3.2.1 Removal and Installation…………………………………….. 3.2.2 Cabin door latches……………………………………………. 3.2.3 Lock …………………………………………………………….
Page 33 3.1.3 Waxing Required Tools: fine-grade wax, batting Parts required: None Level of Maintenance: Line Certification required: Owner Waxing will fill in minor scratches in clear plastic and help protect the surface from further abrasion. Use a good grade of commercial wax applied in a thin, even coat. Bring wax to a high polish by rubbing lightly with a clean, dry flannel cloth.
Page 34 cloudy appearance disappears. A 2000-feet-per-minute surface speed is recommended to prevent overheating and distortion. (Example: 750 rpm polishing machine with a 10 inch buffing bonnet) Note Polishing can be accomplished by hand but will require a considerably longer period of time to attain the same result as produced by a buffing wheel. When buffing is finished, wash area thoroughly and dry with a soft flannel cloth.
Page 35 3.1.5 Replacement 3.1.5.1 Removal Required Tools: Jig saw, crowbar, power drill, abbrasive paper Parts required: None Level of Maintenance: Heavy Certification required: A&P Mechanic Cut out the old window using a jig saw without causing damage to the fuselage. Remove the remaining border of the window by the use of a crowbar and sand of old glue to get a smooth joining surface at the fuselage.
Page 36 l. Apply polyester putty, primer and lacquer to finish your work. Cabin Doors 3.2.1 Removal and Installation Required Tools: None Parts required: None Level of Maintenance: Line Certification required: Owner To remove cabin doors unlock and open the doors, unplug the support gas struts from the door bracket.
Page 37 Figure 3-1. Seats 3.3.1 Description The standard pilot and co-pilot seat is made from one-piece carbon fiber moncoque, equipped with a 3 position fore and aft adjustment. Seat adjustment is not possible while seated. 3.3.2 Adjustment To adjust seat position a push button is provided beneath the forward seat bottom of each seat (left side on left seat, right side on right seat).
Page 38 If the aircraft is to be equipped with the BRS system, follow the instructions in the rescue system installation manual. A special mounting kit, containing the bracket for the rocket motor and some micellaneous parts can be obtained from REMOS Aircraft GmbH or the local distributor. Figure 3-2. illustrates the installation of the rescue system in the aircraft.
Page 39 Warning When working on the ballistic parachute system, ensure that the securing pin is installed to the system and always take great care. An unintended launch of the rocket motor could cause serious injury or death. Figure 3-2. 3.5.2 Safety Belts Required Tools: None Parts required: Safety belts and attachment latches as required.
Page 40 3.5.3 Baggage Pocket Nets Required Tools: 3 mm allen wrench Parts required: Pocket Nets, Allen screws M4x20 as required. Level of Maintenance: Heavy Certification required: LSA Repairman Maintenance or Owner Behind each seat, a mold for lightweight baggage is provided covered by a pocket net.
Page 41 Refer to the G-3 /600 Pilot Operating Handbook, Section 8, for instructions about folding and re-installing wings. 4.1.2 Removal Required Tools: 10/12/13/14 mm wrench, screwdriver and phillips head screwdriver, needle-nosed pliers. REMOS Bolt-Removal-Tool. Parts required: None Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance...
Page 42 Wing removal is most easily accomplished if three men are available to handle the wing. Otherwise, the wing should be supported with a sling when the fastenings are loosened. When using a sling, great care has to be taken not to damage the wing´s surface.
Page 43 4.1.4.1 Installing Strut to Fuselage Note All struts are providing a "Top" marking, which has to point upward when installed, while leading edge (rounded edge) has to point forward. Connect main strut first to the fuselage and support as suitable, so that no damage occures to the attachment and strut bearing.
Page 44 Hold wing in a position to be aligned with the fuselage, leading edge pointing to the ground (wing root pointing forward), so that ball bearing guide cage and ball bracket at the fuselage are side by side. Apply the plastic ball into the guide cage at the wing root, so that it is possible to push it over the bracket at the fuselage and insert it´s fixation screw.
Page 45 Figure 4-2. 4.1.4.4 Installing Support Strut After installing both main struts, the support struts have to be installed in a way, that "Top" marking ist pointing upward and leading edge of the profiled strut is pointing forward. The support struts are connected to main strut and wing attachment, using self locking nuts.
Page 46 Hinges are located on the trailing edge to support the elevator. 4.3.2 Removal and Installation Required Tools: Phillips head screwdriver, Remos Bolt-Removal Tool. Parts required: None Level of Maintenance: Line...
Page 47 Note Stabilizer bolts are different in length, therefor each bolt provide a marking for installation: "V" means forward bolt, "H" means backward bolt. Caution Ensure, that both cowl pins are engaged to the stabilizer bolts. 4.3.3 Repair Horizontal stabilizer repair should be accomplished in accordance with applicable instructions outlined in Section 18.
Page 48 Main Wheel Removal………………………………… 5.1.2.3.1 Main Wheel Disassembly (Matco Brakes)…. 5.1.2.3.2 Inspection and Repair (Matco Brakes)……… 5.1.2.3.3 Reassembly (Matco Brakes)………………… 5.1.2.3.4 Main Wheel Disassembly (REMOS Brakes).. 5.1.2.3.5 Inspection and Repair (REMOS Brakes)…… 5.1.2.3.6 Reassembly (REMOS Brakes)………………. 5.1.2.4 Main Wheel Installation………………………………. 5.1.3 Nose Gear……………………………………………………...
Page 49 The webbed wheels having two aluminum flanges and a hub are manufactured by REMOS Aircraft GmbH. The flanges are attached to the wheel hub by thru-bolts and nuts as shown in figure 5-2. During assembly of the main wheel the thru-bold nuts or capscrews, as applicable, shall be tightened evenly and torqued to the value specified in figure 5-2.
Page 50 Remove cable ties securing the brake line distributor to the fuselage (accessible when baggage compartment is removed). Drain hydraulic brake fluid from brake lines. Disconnect hydraulic brake line at the brake line distributor. Hoist or jack aircraft in accordance with Section 2. Remove both bolts attaching main gear to fuselage.
Page 51 Figure 5-1. 5.1.2.3 Main Wheel Removal Required Tools: 11/17/19 mm wrench, wire cutting pliers, plastic hose. Parts required: None Level of Maintenance: Line Certification required: LSA Repairman Maintenance or Owner To remove main wheel follow steps a to d, outlined in paragraph 5.1.2.1 and then proceed as described below (refer to figure 5-1.): Hoist or jack aircraft in accordance with Section 2.
Page 52 5.1.2.3.1 Main Wheel Disassembly (Matco Brakes) Required Tools: 4 & 5 mm allen wrench, 6 mm wrench. Parts required: None Level of Maintenance: Line Certification required: LSA Repairman Maintenance Unscrew brake disc and withdraw complete brake assembly from wheel hub. Remove valve core and deflate tire.
Page 53 Remove thru-bolts and separate wheel halves, removing tire, tube, hub and torque plate. Remove wheel bearings from wheel hub. 5.1.2.3.5 Main Wheel Inspection and Repair (REMOS Brakes) Refer to paragraph 5.1.2.3.2 Section 5-6...
Page 54 5.1.2.3.6 Main Wheel Reassembly (REMOS Brakes) Refer to paragraph 5.1.2.3.3 5.1.2.4 Main Wheel Installation Required Tools: 11/17/19 mm wrench. Parts required: DOT 4 hydraulic fluid, cable ties, cotter pin (2 x 25 mm), bleed- kit. Level of Maintenance: Line Certification required: A&P Mechanic or LSA Repairman Maintenance Main Wheel Installation is prinizpal done in reverse order to removal.
Page 55 Figure 5-2. Section 5-8...
Page 56 5.1.3 Nose Gear 5.1.3.1 Removal and Installation Required Tools: Screwdriver, 8/10/17 mm wrench. Parts required: Self-locking nut (M6), 2 x self-locking nut (M5), and safety-wire (1.0 mm). Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance Remove engine cowling for access. Weight or tie-down tail of aircraft to raise nose wheel off the floor.
Page 57 WARNING Injury can result from attempting to separate wheel halves with the tire inflated. Avoid damaging wheel flanges when breaking tire beads loose. A scratch, gouge, or nick may cause wheel failure. Remove thru-bolts and separate wheel halves, removing tire, tube and hub. Remove wheel bearings from wheel hub.
Page 58 Figure 5-3. Section 5-11...
Page 59 5.1.3.4 Nose Wheel Steering System Nose wheel steering is accomplished through the use of the rudder pedals. Steering rod assemblies connect the nose gear steering. 5.1.3.4.1 Steering Adjustment Since the nose wheel steering and rudder system are interconnected, adjustment to one system may affect the other system.
Page 60 5.2.2 Brake Master Cylinder (refer to figure 5-4.) The brake master cylinder, located between seats, is actuated by applying pressure at the top of the brake lever. A small reservoir is incorporated onto the master cylinder for the fluid supply. Figure 5-4.
Page 61 Matco brakes. When equipped with the REMOS Hydraulic Brakes, the disc is floating, while the brake assembly is a fixed type, featuring a double piston system.
Page 62 Check brake lining for deterioration and maximum permissible wear. See paragraph 5.2.4.5. Inspect brake cylinder bore for scoring. A scored cylinder will leak or cause repid O-ring wear. Install new brake cylinder. If the anchor bolts on the brake assmebly are nicked or gouged, they shall be sanded smooth to prevent binding with the pressure plate or torque plate.
Page 63 Position pressure plate on anchor bolts and place cylinder in position so that anchor bolts slide into the torque plate. Install back plate with bolts and washers. 5.2.4.7 Brake Lining Installation (REMOS Brakes) Required Tools: None Parts required: Brake Linings, Copper Grease...
Page 64 5.2.6 Parking Brake System (refer to figure 5-4.) The parking brake system consists of a control lever behind the master brake cylinder. To engage the parking brake, depress the brake lever and rotate the parking brake control lever to the right. To release the parking brake, rotate the control lever counter clockwise.
Page 65 Section 6 Structures – Aileron Control System Table of Contents Page Aileron Control System, Description……………………………….. 6.1.1 Trouble Shooting……………………………………………… 6.1.2 Control Stick Linkage, Description………………………….. 6.1.2.1 Removal and Installation…………………………….. 6.1.3 Aileron Control Rods, Description…………………………... 6.1.3.1 Removal and Installation…………………………….. 6.1.4 Bellcranks, Description……………………………………….. 6.1.4.1 Removal and Installation……………………………..
Page 66 6.1.2 Control Stick Linkage, Description Both control sticks are linked together by a control rod system to ensure synchron movement. The linkage is located beneath two fiberglass-panels on the floor of the cabin right in front of the seats. A translator connects the control stick linkage to the aileron linkage, which uses several bellcranks to establish the connection to the control surfaces.
Page 67 6.1.3.1 Removal and Installation Required Tools: 10 mm wrench Parts required: self-locking nuts as required. Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance To get access to the aileron control rods, both wings provide two access flaps. Routing of the control rods within the fuselage will be visible, if baggage compartment is removed (refer to Section 3).
Page 68 6.1.5.2 Repair Repair is limited to replace copper bushings or hinge bolts and restoring dents or smaller cracks on edges. Since ailerons are designed as sandwich construction parts, it is strongly recommended to replace or return to factory for repair, if larger deterioration of the skin is detected.
Page 69 Figure 6-1. Section 6-5...
Page 70 Figure 6-1. (continued) Section 6-6...
Page 71 Section 7 Structures – Wing Flap Control System Table of Contents Page Wing Flap Control System, Description……………………………. 7.1.1 Operational Check……………………………………………. 7.1.2 Trouble Shooting……………………………………………… 7.1.3 Flap Motor and Transmission Assembly…………………… 7.1.3.1 Removal and Installation…………………………….. 7.1.3.2 Repair………………………………………………….. 7.1.4 Flap Control System………………………………………….. 7.1.4.1 Removal and Installation……………………………..
Page 72 With flaps full UP, mount an inclinometer on one flap and set to 0°. Lower flaps to full DOWN position and check flap angle as specified in figure 1-1. Check approximate mid-range percentage setting against degrees as indicated on inclinometer. Inspect flap hinges for free play or binding (if necessary disconnect motor assembly from actuator lever inside the cabin).
Page 73 7.1.3 Flap Motor and Transmission Assembly 7.1.3.1 Removal and Installation Required Tools: 5 mm allen wrench, 10 & 13 mm wrench, phillips head screwdriver. Parts required: 3 x self-locking nut (M6). Level of Maintenance: Line Certification required: LSA Repairman Maintenance An illustration of the flap motor assembly is given in figure 7-2.
Page 74 Operating Handbook, Section 8). Refer to figure 7-2. for details on removal and installation. Unscrew the drive-shaft support bearing (10). Withdraw the drive-shaft (9) from the fuselage. Unscrew actuation lever clamping screws (8). Note To remove the actuation lever from the drive shaft, the whole assembly has to heated up to 300°F.
Page 75 7.1.6 Flaps 7.1.6.1 Removal and Installation (refer to figure 7-1.) Required Tools: 10 mm wrench Parts required: 4 x cotter pin (1.6 x 20 mm), self-locking nut (M6). Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance Run flaps to full DOWN position.
Page 76 Figure 7-1. Section 7-6...
Page 77 Figure 7-2. Section 7-7...
Page 78 7.1.6.2 Repair Repair is limited to replace copper bushings or hinge bolts and restoring dents or smaller cracks on edges. Since flaps are designed as carbon fiber sandwich components, it is strongly recommended to replace or return to factory for repair, if larger damage or deterioration of the skin is dedicated.
Page 79 in figure 1-2. (Secure clamp screws, using Loctite 243). Note After applying Loctite 641 to the actuator lever clamp, you have 30 minutes until the Loctite will cure, further correction to the adjustment can only be done within this time. Perform a check flight and ensure that aircraft maintains heading at full payload, with both seats occupied.
Page 80 Section 8 Structures – Elevator Control System Table of Contents Page Elevator Control System, Description……………………………… 8.1.1 Trouble Shooting……………………………………………… 8.1.2 Elevators………………………………………………………. 8.1.2.1 Removal and Installation…………………………….. 8.1.2.2 Repair………………………………………………….. 8.1.3 Bellcranks……………………………………………………… 8.1.3.1 Removal and Installation…………………………….. 8.1.4 Rigging………………………………………………………… Elevator Control System, Description The elevator is operated by the pullling/pushing power transmitted from the control stick through a bellcrank and a push-pull tube.
Page 81 8.1.2 Elevator 8.1.2.1 Removal and Installation (refer to figure 8-1.) Required Tools: 10 mm wrench Parts required: self-locking nut (M6) Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance Disconnect quick release connector at the aft end of push-pull tube (x). Disconnect trim wiring at terminal on fuselage tail.
Page 82 8.1.4 Rigging Required Tools: 14 mm open-end wrench Parts required: Loctite 243 (medium strength) Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance Locate neutral position of elevators by streamlining elevators with stabilizer. Place an inclinometer on the elevator and set to zero. Check for centered positon of control stick.
Page 83 Figure 8-1. Section 8-4...
Page 84 Section 9 Structures – Elevator Trim Control System Table of Contents Page Elevator Trim Control System, Description………………………… 9.1.1 Trouble Shooting……………………………………………… 9.1.2 Trim Tab……………………………………………………….. 9.1.2.1 Inspection and Repair………………………………… 9.1.3 Trim Tab Servo..............9.1.3.1 Removal and Installation…………………………….. 9.1.4 Trim Control System…………………………………………. 9.1.4.1 Removal and Installation……………………………..
Page 85 9.1.2 Trim Tab 9.1.2.1 Inspection and Repair The trim tab panel is attached to the elevator by a flexible composite hinge, therefore it can not be removed from the elevator. The flexible hinge should be inspected due to cracks during regular service intervals. It may be find that cracks in the paint of the hinge will occur which are not structural and does not need any servicing.
Page 86 9.1.5 Indicating system To indicate the position of trim tab, an LED-indicator is installed in the switch panel. Power to the indicator is supplied by the trim tab servo. 9.1.5.1 Removal and Installation Required Tools: 2.5 & 3 mm allen wrench, 5.5 & 10 mm wrench, edge-cutter. Parts required: Insulating tape, cable ties, 2 x self-locking nut (M3).
Page 87 Figure 9-1. Section 9-4...
Page 88 Section 10 Structures – Rudder Control System Table of Contents Page 10.1 Rudder Control System, Description……………………………….. 10-1 10.1.1 Trouble Shooting……………………………………………… 10-1 10.1.2 Rudder Pedal Assembly……………………………………... 10-2 10.1.2.1 Removal and Installation…………………………….. 10-2 10.1.3 Rudder…………………………………………………………. 10-2 10.1.3.1 Removal and Installation…………………………….. 10-2 10.1.3.2 Repair…………………………………………………..
Page 89 Lost motion between Insufficient cable tension. Adjust cable tension in rudder pedals and rudder. accordance with paragraph 10.1.5. Incorrect rudder travel. Incorrect rigging. Rig system in accordance with paragraph 10.1.5. 10.1.2 Rudder Pedal Assembly (refer to figure 10-1.) 10.1.2.1 Removal and Installation Required Tools: 8/10/17 mm wrench.
Page 90 Figure 10-1. 10.1.4 Cables and Pulleys 10.1.4.1 Removal and Installation Required Tools: 8 & 10 mm wrench, phillips head screwdriver. Parts required: 4 x self-locking nut (M6). Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance Remove seats and baggage compartment (refer to Section 3). Disconnect cables at rudder pedals.
Page 91 10.1.5 Rigging Required Tools: 8 mm wrench Parts required: Safetying wire Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance Align rudder with fin to neutral position. Adjust cables at clevis to achieve a neutral pedal setting. Adjust cable tension for proper operation and pedal motion without binding.
Page 92 Section 11 Engine Table of Contents Page 11.1 Engine Cowling, Description………………………………………… 11-2 11.1.1 Removal and Installation…………………………………….. 11-2 11.1.2 Cleaning and Inspection……………………………………... 11-2 11.1.3 Repair………………………………………………………….. 11-3 11.2 Engine, Description…………………………………………………... 11-3 11.2.1 Engine Date …………………………………………………... 11-3 11.2.2 Trouble Shooting……………………………………………… 11-4 11.2.3 Removal……………………………………………………….. 11-7 11.2.4 Cleaning………………………………………………………..
Page 93 Table of Contents (continued) Page 11.9 Starting System, Description………………………………………… 11-21 11.9.1 Trouble Shooting …………………………………………….. 11-22 11.9.2 Removal and Installation ……………………………………. 11-22 11.10 Exhaust System, Description………………………………………… 11-22 11.10.1 Removal………………………………………………………... 11-23 11.10.2 Inspection………………………………………………………. 11-23 11.10.3 Installation……………………………………………………… 11-23 11.11 Extreme Weather Maintenance……………………………………… 11-23 11.11.1 Cold Weather…………………………………………………..
Page 94 11.1.5 Repair Required Tools: As required Parts required: Epoxy Resin, carbon fibre tape, rowings, fabrics. Level of Maintenance: Heavy Certification required: A&P Mechanic or LSA Repairman Maintenance If cowling skins are extensively damaged, new complete sections of the cowling should be installed. If cracks are detected in the carbon fiber cowl segments, they may be repaired using L285 Epoxy Resin or similar (R&G L20), reinforcing with suitable carbon fiber fabrics.
Page 95 Max………………………………………………….. 285° F 285° F Min…………………………………………………... 120° F 120° F Normal………………………………………………. 190-230° F 190-230° F Cylinder Head Temperature Max. (observation at hottest cylinder, #2 or #3)… 300° F 300° F Normal………………………………………………. 167-230° F 167-230°F Engine Start, Operating Temperature Max………………………………………………….. 120° F 120°...
Page 96 Water in fuel system. Drain fuel tank sump, fuel lines and carburetors. Excessive starter slippage. Replace starter motor. Engine will not run at idling Idle speed incorrectly Refer to paragraph 11.5.2 speed. adjusted. Carburetor idling jet Clean carburetor. plugged. Air leak in intake manifold. Tighten loose connections or replace damaged parts.
Page 97 Incorrect carburetor Synchronize carburetors in synchronizing. accordance to Rotax maintenance manual. Incorrect carburetor Adjust carburetors in mixture setting. accordance with Rotax maintenance manual. High cylinder head Low grade fuel. Drain and fill with correct temperature. grade of fuel. Refer to Section 2.
Page 98 Open battery circuit by disconnecting battery cable(s) at the battery. Insulate cable terminal(s) as a safety precaution. Disconnect all wiring at the terminals on the firewall (located in the REMOS Connector-Box on the left-hand side of the firewall). Disconnect wiring at voltage regulator terminal (located on lower left-hand side of the firewall) and remove cable ties and clamps as required.
Page 99 l. Disconnect carburetor heat control from arm on carburetor heat air intake housing assembly. Remove cable ties and pull control aft clear of the engine and disconnect cabin heat hose from heater shell at exhaust system. WARNING Residual fuel and oil draining from disconnected lines and hose is a fire hazard. Use care to prevent accumulation of such fuel and oil when lines or hose are disconnected.
Page 100 11.2.5 Accessories Removal Removal of engine accessories for overhaul or for engine replacement involves stripping the engine of parts, accessories, and components to reduce the engine assembly to the bare engine. During removal, carefully examine removed items and tag defective parts for repair or replacement by a new part. Note Items easily confused with similar items should be tagged to provide a means of identification when being installed on a new engine.
Page 101 Connect wires and cables as follows: 1. Ground wiring to firewall. 2. Wiring to voltage regulator at firewall. 3. Engine wiring to terminal at Remos Connector-Box on firewall. Install all clamps attaching wires and cables to engine, engine mount, or attached brackets.
Page 102 and tightness of all components. Bleed engine oil sysem in accordance with engine manufacturer maintenance manual. Clean and install carburetor air filter. Be sure all hot and cold air ducts are installed and connected. Perform engine run-up and make final adjustments on engine controls. Install engine cowling.
Page 103 11.2.9 Flexible Fluid Hoses 11.2.9.1 Leak Test After each 100 hours of engine operation, all flexible fluid hoses in the engine compartment should be checked for leaks as follows: Examine the exterior of hoses for evidence of leakage or wetness. Hoses found leaking should be replaced.
Page 104 11.3 Engine Mount, Description (refer to figure 11-2.) The engine mount is composed of sections of tubing welded together and reinforced with welded gussets. The purpose of the engine mount, is to support the engine and attach the engine to the airframe. The engine is attached to the mount with shock- mount assemblies which absorb engine vibrations.
Page 105 Trouble Probable Cause Remedy No oil pressure. No oil in system. Fill system with proper grade and quantity of oil. Refer to Section 1. Oil pressure line broken, Replace or connect. disconnected or pinched. Defective oil pressure Replace oil pressure sensor.
Page 106 High oil temperature. Excessive rate of climb. Avoid low airspeed. Closed oil cooler flap. Move flap to "open" position. Defective oil temperature Replace oil temperature sensor. sensor. Defectiv oil temperature Replace or Repair Rotax gauge. Flydat. Low oil supply. Refer to Rotax Maintenance Manual.
Page 107 If the filter is under-torqued, oil leakage will occur. If the filter is over-torqued, the filter can possibly be deformed, again causing oil leakage. Lubricate rubber gasket of new filter element with clean engine oil. A dry gasket can cause a false torque value, again resulting in oil leakage. 11.5 Engine Fuel System, Description The engine is equipped with two carburetors mounted at the upper side of the engine.
Page 108 Set the throttle stop screws to obtain between 1700 and 1800 rpm, with throttle control pulled full out against idle stop. Check that both idle stop screws contact its idle stop brackets at the same time and readjust if necessary. Apply laquer to each idle stop screw to secure proper safteying.
Page 109 11.7.1 Magneto Removal and Installation Magnetos are located at the back side of the engine, and to replace them it is necessary to remove the induction airbox first (refer to paragraph 11.5.1). After removing the protection cover on the engine back, access to the magnetos is enabled.
Page 110 11.8 Engine Controls, Description Engine controls of the push-pull type include the throttle, choke, oil temperature regulator and carburetor heat controls. The engine controls are equipped with position-locking devices which prevent vibration-induced “creeping” of the controls. Figure 11-3. 11.8.1 Rigging When adjusting any engine control, it is important to check that the control slides smoothly throughout its full range of travel, that it locks securely if equipped with a locking device, and the arm or lever which it operates moves through its full arc of...
Page 111 11.8.1.1 Throttle Control Required Tools: 8 & 10 mm open-end wrench Parts required: Lock screw Level of Maintenance: Line Certification required: A&P Mechanic or LSA Repairman Maintenance Note Before rigging throttle control ensure that control cable are in proper condition. Push throttle to full throttle position and check that both actuator arms on carburetor achieve maximum position.
Page 112 11.8.1.3 Carburetor Heat Control Note Rigging the carburetor heat control is only possible, if a new control is installed to the aircraft. To replace, cut off the controle wire at the carburetor heat housing end and pull out the control knob with the attached control wire from it´s cover tube. Insert a new control wire to the carburetor heat conduit.
Page 113 11.9.1 Trouble Shooting Trouble Probable Cause Remedy Starter will not operate. Defective master switch or Install new switch or wires. circuit. Defective starter switch or Install new switch or wires. switch circuit. Defective starter motor. Remove, repair or install new starter motor. Starter motor runs, but Starter motor shaft broken.
Page 114 11.10.1 Removal 11.45.1 Required Tools: Screwdriver, gripper, 12 & 13 mm wrench 11.45.2 Parts required: Heat resistant silicone, 8 x self-locking copper nut (M8). 11.45.3 Level of Maintenance: Line 11.45.4 Certification required: A&P Mechanic or LSA Repairman Maintenance Remove engine cowling as required for access. Disconnect flexible hose from heater shell on muffler assembly.
Page 115 starting to periods not longer than 10 seconds and with a well charged battery (adding a second battery will not improve cold starts). 11.11.2 Hot Weather Engine mis-starts characterized by weak, intermittent explosions followed by puffs of black smoke from the exhaust are caused by flooding. This situation is more apt to develop in hot weather or when the engine is hot.
Page 116 Changed 1 Section 12 Fuel System Table of Contents Page 12.1 Fuel System Description…………………………………………….. 12-1 12.1.1 Precautions……………………………………………………. 12-1 12.1.2 Trouble Shooting……………………………………………… 12-2 12.1.3 Fuel Tank Description………………………………………... 12-4 12.1.3.1 Removal and Installation…………………………….. 12-4 12.1.4 Fuel Quantity Transmitter……………………………………. 12-6 12.1.4.1 Removal and Installation…………………………….. 12-6 12.1.5 Electrical Fuel Pump………………………………………….
Page 117 Changed 1 1. During all fueling, defueling, tank purging, and tank repairing or disassembly, ground the aircraft to a suitable ground stake. Use the engine or negative battery terminal grounding. 2. Residual fuel draining from lines and hose constitutes a fire hazard. Use caution to prevent the accumulation of fuel when lines or hoses are disconnected.
Page 118 Changed 1 Figure 12-1. Section 12-3...
Page 119 Changed 1 12.1.3 Fuel Tank Description (refer to figure 12-2) A rigid carbon fiber tank is installed behind the right side of the cabin bulkhead inside the fuselage. A fuel tank sump drain valve is provided for draining trapped water and sediment.
Page 120 Changed 1 Figure 12-3. Section 12-5...
Page 121 Changed 1 12.1.4 Fuel Quantity Transmitter A fuel quantity transmitter is installed in the top of the fuel tank. A complete description, along with procedures for calibration and troubleshooting are contained in Section 15. 12.1.4.1 Removal and Installation (refer to figure 12-4 and 12-5) Required Tools: Screwdriver Parts required: Cable ties Level of Maintenance: Heavy...
Page 122 Changed 1 Figure 12-5. 12.1.5 Electrical Fuel Pump An electrical fuel pump is installed to the fuel line, located adjacent to the fuel tank. Power to the pump is provided by a switch at the switch panel. 12.1.5.1 Removal and Installation (refer to figure 12-6) Required Tools: Phillips head screwdriver, 6mm allen wrench, 10 mm wrench.
Page 123 Changed 1 Figure 12-6. Section 12-8...
Page 124 Changed 1 12.1.6 Fuel Filter An additional screen type fuel filter is attached to the fuel hose at the inlet of the electrical fuel pump. Refer to Section 2 for replacement intervals of the fuel filter. 12.1.6.1 Removal and Installation (refer to figure 12-6) Required Tools: Phillips head screwdriver, clamp tongs.
Page 125 Changed 1 12.1.8 Fuel Shut-Off Valve The fuel shut-off valve is a two-position ON-OFF valve, located in the center section of the cabin in front of the brake lever. It is recommended that the valve be replaced and not repaired. 12.1.8.1 Removal and Installation (refer to figure 12-8) Required Tools: 10-13 mm wrench, edge cutter, phillips head screwdriver.
Page 126 Changed 1 12.1.9 Fuel Drain Valve A fuel drain valve is installed to the bottom of the fuel tank. Access is possible from beneath the fuselage adjacent to the main gear. To drain fuel, push up the white plastic tube. If draining of the whole system is required, push up the plastic tube and rotate 90°...
Page 127 Changed 1 12.1.10 Fuel Distributor System, Description (refer to figure 12-10 and 12-11.) A fuel distributor is installed to provide fuel for both carburetors. The fuel distributor is located on top of the engine. Pressurized fuel from the fuel pump is routed to both carburetors while surplus of fuel flows back to the fuel tank through a return hose.
Page 128 Changed 1 Figure 12-10. Section 12-13...
Page 129 Changed 1 Figure 12-11. Section 12-14...
Page 130 Changed 1 12.1.11 Firewall Ports and Fuel Pressure Gauge (refer to figure 12-12.) The fuel distributor system is connected to fuel lines routed inside the cabin using the ports C1 and C2 (see paragraph 12.1.10). With the basic installation of the aircraft a fuel pressure gauge is provided, connected to port C3.
Page 131 13.1 Propeller Fixed Pitch A composite-wood, fixed-pitch propeller, equipped with either an aluminum or a plastic spinner, is used on the REMOS G3 aircraft. Figure 13-1. 13.1.1 Repair Repair of a wood propeller first involves evaluating the damage and determining whether the repair is to be a major or minor one.
Page 132 Changed 1 defective paint or small dents has to be rated as major repair. Refer also to propeller manufacturers manual for further instruction. We strongly recommend to replace propeller if any cracks, deteriorations of the skin or extended dents are determind. 13.1.2 Removal (refer to figure 13-2.) Required Tools: 3 &...
Page 133 Changed 1 Figure 13-2. Section 13-3...
Page 134 (Sensenich 2A0-R5R70-EN) A carbon fiber, ground adjustable Sensenich propeller, equipped with either an aluminum or a plastic spinner, is used on the REMOS G3 aircraft as option. It is mandatory to maintain the servicing intervalls given in the propeller manufacturers manual.
Page 135 Changed 1 13.2.1 Repair Repair of a carbon fiber propeller first involves evaluating the damage and determining whether the repair is to be a major or minor one. In general all damages except defective paint or small dents has to be rated as major repair. Refer also to propeller manufacturers manual for further instruction.
Page 136 Changed 1 Figure 13-4. Section 13-6...
Page 137 Changed 1 13.3.3 Installation (refer to figure 13-4.) Required Tools: 3 & 6 mm allen wrench, 7/13 mm wrench, torque wrench. Parts required: Silicone compound, Loctite 243 medium strength 8 x self-locking nut (M4). Level of Maintenance: Line Certification required: LSA Repairman Maintenance or Owner Clean mating surfaces of propeller, gearbox flange and spinner bulkheads.
Page 138 Changed 1 Warning Be sure master switch is in OFF position and key removed from starter switch before turning propeller. If rigging is not done as step of the propeller installation process, propeller spinner dome has to be removed first (refer to paragraph 13.2.2). Set propeller pitch using the pitch gauge (5) provided on the pitch cylinder (2) and hub cover half (1).
Page 139 Changed 1 Section 14 Utility Systems Table of Contents Page 14.1 Heating System, Description………………………………………… 14-1 14.1.1 Operation………………………………………………………. 14-1 14.1.2 Trouble Shooting……………………………………………… 14-1 14.1.3 Removal, Installation and Repair…………………………… 14-3 14.2 Ventilating System, Description…………………………………….. 14-4 14.2.1 Operation………………………………………………………. 14-4 14.2.2 Trouble Shooting……………………………………………… 14-4 14.2.3 Removal, Installation and Repair……………………………...
Page 140 Changed 1 Figure 14-1. Section 14-2...
Page 141 Changed 1 14.1.3 Removal, Installation and Repair Required Tools: Phillips head screwdriver, riveting pliers Parts required: Hoses and hose clamps as required, rivets 3x8mm (3x). Level of Maintenance: Line Certification required: LSA Repairman Maintenance or Owner Figure 14-1 and 14-2 illustrates the heating and ventilating systems, and may be used as a guide during removal, installation and repair of heating system components.
Page 142 Changed 1 14.2 Ventilating System, Description The ventilating system is comprised of a naca-style fresh air-scoop mounted in the right side of the upper cowling. A shut-off valve is located on the right side of the firewall, operated by a push-pull control marked “Cold”, located beneath the switch panel, regulates the volume of fresh air entering the system.
Page 143 Changed 1 Section 15 Instruments and Instrument System Table of Contents Page 15.1 Instruments and Instrument Systems, General…………………… 15-2 15.2 Instrument Panel, Description………………………………………. 15-2 15.2.1 Removal and Installation…………………………………….. 15-2 15.2.1.1 Stationary Panel………………………………………. 15-2 15.2.1.2 Shock Mount Panel…………………………………… 15-3 15.2.2 Shock Mounts…………………………………………………. 15-3 15.2.3 Instrumens and Avionics.…………………………………….
Page 144 Changed 1 15.1 Instrument and Instrument Systems, General This section describes typical instrument installations and their respective operating systems. Emphasis is placed on trouble shooting and corrective measures only. It does not deal with specific instrument repairs since this usually requires special equipment and data and should be handled by instrument specialists.
Page 145 Changed 1 Do not overtighten panel fixing screws at reinstallation, because this would cause the ABS decorative cover to crack. 15.2.1.2 Shock Mount Panel (refer to figure 15-2) The shock mounted panels consist of an aluminum support frame and a decorative ABS cover attached to the cockpit main-frame via rubber shock mounts.
Page 146 Changed 1 Figure 15-1. Section 15-4...
Page 147 Changed 1 Figure 15-2. Section 15-5...
Page 148 Changed 1 Figure 15-3. Section 15-6...
Page 149 Changed 1 Figure 15-4. Section 15-7...
Page 150 Changed 1 Figure 15-5. Section 15-8...
Page 151 Changed 1 Figure 15-6. Section 15-9...
Page 152 Changed 1 Figure 15-7. Section 15-10...
Page 153 Changed 1 15.3 Pitot and Static System, Description (refer to figure 15-8 to 15-12) The pitot system conveys ram air pressure to the airspeed indicator. The static system vents vertical speed indicator, altimeter and airspeed indicator to atmospheric pressure through plastic hoses connected to a static port on each side of the fuselage.
Page 154 Changed 1 repaired by an “appropriated rated repair station” or replaced. If static pressure system is at fault, use following procedure to locate leakage. Attach a source of positive pressure to static source opening. Caution Do not apply positive pressure with airspeed indicator or vertical speed indicator connected to static pressure system.
Page 155 Changed 1 Figure 15-8. Section 15-13...
Page 156 Changed 1 Figure 15-9. Section 15-14...
Page 157 Changed 1 Figure 15-10. Section 15-15...
Page 158 Changed 1 Figure 15-11. Section 15-16...
Page 159 Changed 1 Figure 15-12. Section 15-17...
Page 160 Changed 1 15.3.5 Removing and Installation of Components (refer to figure 15-8 to 15-12) Required Tools: Edge cutter Parts required: Cable ties, hoses as required. Level of Maintenance: Line Certification required: LSA Repairman Maintenance or Owner To remove pitot tube, unscrew union nut and withdraw tube from support tube. A pitot line running within the left wing is fixed inside the wing and can not be removed.
Page 161 Changed 1 Excessive tubing vibration. Check clamps, cable ties and line connections for security. 15.3.8 Trouble Shooting Altimeter Trouble Probable Cause Remedy Instrument fails to operate. Static line plugged. Check line for obstructions. Blow out lines. Defective mechanism. Substitute known-good altimeter and check reading.
Page 162 Changed 1 15.4 Engine Indicators 15.4.1 Rotax Flydat System The Flydat represents an instrument specially developed for Rotax Aircraft engines for the indication and acquisitation of engine operating data readily accessible for the pilot. The Flydat provides the following indicators: Engine speed, cylinder head temperature, oil temperature, oil pressure, exhaust gas temperatures, operation hours.
Page 163 Changed 1 Defective Flydat. Substitute known-good Flydat and check operation. Replace Flydat. 15.4.2 Fuel Quantity Indicating System, Description The electric type fuel quantity indicator is used in conjunction with a float – operated variable – resistance transmitter in the fuel tank. The full position of float produces a maximum resistance (~180 ohms) through transmitter, permitting maximum pointer deflection.
Page 164 Changed 1 Defective transmitter. Check resistance of transmitter as outlined in paragraph 15.4.2. Off calibration. Defective indicator. Substitute known-good indicator. Replace indicator. Defective transmitter. Substitute known-good indicator. Recalibrate or replace. Sluggish indicator Defective indicator. Substitute known-good operation. indicator. Replace indicator. Erratic readings.
Page 165 Changed 1 mounts from cockpit main-frame. Disconnect wiring and hoses and remove panel. Remove manifold temperature indicator. Reverse preceding steps for reinstallation. Note Do not overtighten cover fixing screws at reinstallation, because this would cause the ABS decorative cover to crack. 15.4.3.2 Trouble Shooting Trouble Probable Cause...
Page 166 Changed 1 Section 16 Electrical Systems Table of Contents Page 16.1 Electrical System, General…………………………………………... 16-2 16.2 Electrical Power Supply System, Description……………………... 16-2 16.2.1 Master Wiring System………………………………....16-2 16.2.2 Switch Panel…………………………………………....16-2 16.2.3 Master Switch…………………………………………………. 16-2 16.2.4 Avionics Master Switch………………………………………. 16-3 16.2.5 Flap Drive Switch……………………………………....
Page 167 Changed 1 Table of Contents (continued) Page 16.8.3 Night VFR Lighting System, Description…………………… 16-12 16.8.3.1 Landing Light – LED-Type, Description……………. 16-12 16.8.3.1.1 Installation……………………………………... 16-12 16.8.3.2 Anti-Collision Lights – LED-Type, Description…….. 16-12 16.8.3.2.1 Installation……………………………………… 16-12 16.8.3.3 Navigation Lights – LED-Type, Description………... 16-15 16.8.3.3.1 Installation………………………………………...
Page 168 Changed 1 16.2.4 Avionics Master Switch When the avionics master switch is operated, power to the avionics bus system is enabled. The avionics bus system provides power to all electronic devices like radio, intercom, transponder, GPS, attitude indicator, directional indicator, EFIS system (if fitted).
Page 169 Changed 1 16.3 Battery Power System 16.3.1 Battery, Description The battery is 12 volts and is approximately 12 ampere-hour capacity. The battery is mounted on left the forward side of the firewall. The factory installed battery is of a sealed type and requires no maintenance. 16.3.2 Removal and Installation Required Tools: Screwdriver, 10 mm wrench.
Page 170 Changed 1 Faulty wiring. 3. Check voltage on master fuse/circuit breaker. Voltage shall not indicate more then 0.3 volts below battery voltage. Replace defective wiring, master switch or connectors. 16.3.4 Cleaning the Battery For maximum efficiency the battery and connections should be kept clean at all times.
Page 171 Changed 1 16.5 Voltage Rectifier Regulater, Description The rectifier regulater is located on the left forward side of the firewall. Feeding wires from the alternator (left side of ignition housing on the engine) are routed directly to the regulator. The resulting dc output is applied to the aircraft battery and master wiring system.
Page 172 Changed 1 Defective switch. 3. Check voltage at light with master switch and landing light switch ON. Should read battery voltage. Replace switch. All nav lights out. Short circuit in wiring. 1. Inspect fuse/circuit breaker. If open, proceed to step 2. If OK, proceed to step 3.
Page 173 Changed 1 16.6.2 Navigation Lights, Description The navigation lights are located on each wing tip. The lights are controlled by a rocker type switch located on the switch panel. 16.6.2.1 Removal and Installation Required Tools: Phillips head screwdriver Parts required: None Level of Maintenance: Line Certification required: Owner Unscrew and remove colored protective cover.
Page 174 Changed 1 16.7 External Receptacle, Description A receptacle for connecting external equipment like GPS is installed on top of the rear cabin bulkhead, between both seats. The receptacle provides 12 volt (positive lead on center terminal). A special adapter to connect a cigar lighter plug can be obtained from the factory or at most automobile parts suppliers.
Page 175 Changed 1 Figure 16-1. 16.8.2 Landing Light, Description The landing light is mounted to the bottom of the lower engine cowling. This position facilitates the use of one lamp as both a landing and taxi light. A light cover provides weather protection for the lamp.
Page 176 Changed 1 located forward the firewall to the lamp position on the lower cowling. The position light set contains required wiring, including connectors, terminals, lamp assembly and fasteners. The complete lamp set can be obtained from the factory. Figure 16-2. Section 16-11...
Page 177 Changed 1 16.8.3 Night VFR Lighting System, Description For Night-VFR use the REMOS G-3/600 has to be equipped with the REMOS Night- VFR Kit, consisting of landing light, navigation lights, anti-collision-lights, tail light and a cockpit lighting system. All systems are advanced LED-type devices matching with the ASTM requirements.
Page 178 Changed 1 Figure 16-3. Section 16-13...
Page 179 Changed 1 To install ACL flash light to the belly, follow the description below and refer to figure 16-4. Disconnect battery leads and insulate as safety precaution. Remove baggage compartment (refer to Section 3). Drill holes for ACL installation according to template provided with ACL-light and measures illustrated in figure 16-4.
Page 180 Unscrew nav-light protective cover, remove and unplug nav light. Drill holes to tip rib as illustrated (1) and apply rivnuts. Connect REMOS LED position light assembly (4) to wiring harness inside wing and install as illustrated. Secure harnesses with cable ties as required and attach access flap (4).
Page 181 Changed 1 Figure 16-5. Section 16-16...
Page 182 Changed 1 Figure 16-6. 16.8.3.5 Cockpit Lighting System – LED-Type, Description The cockpit lighting system consists from three LED-arrays mounted below the top border of the cokcpit main frame. At the left border of the cockpit frame a dim control is located.
Page 183 Changed 1 Figure 16-7. Section 16-18...
Page 184 Changed 1 16.9 Electrical Load Analysis Chart 16.9.1 Standard Equipment (none Night VFR) The following table does show the load analyis for the REMOS G-3/600, without Night-VFR package. Standard Equipment Amps (running load) Fuel indicator……………………………………………………. Fuel pump……………………………………………………….. Anti collision strobe light………………………………………..
Page 185 Changed 1 16.9.2 Night VFR Equipment The following table does show the load analyis for the REMOS G-3/600, equipped with REMOS Night-VFR package. Standard Equipment Amps (running load) Fuel indicator……………………………………………………. Fuel pump……………………………………………………….. Anti collision strobe lights (LED-type)………………………… Navigation lights (LED-type)…………………………………...
Page 186 Section 18 Structural Repair Table of Contents Page 18.1 Structural Repair Criteria…............18-2 18.1.1 General Consideration for Composite Repairs……………. 18-2 18.1.2 Equipment and Tools………………………………………… 18-2 18.1.2.1 Support Stands……………………………………….. 18-2 18.1.2.2 Fuselage Repair Jigs…………………………………. 18-3 18.1.2.3 Wing Jigs ……………………………………………… 18-3 18.1.3 Wing, Stabilizer Angle of Incidence…………………………...
Page 187 Table of Contents (continued) Page 18.12 Engine Mount, Description……..……………………………………. 18-8 18.12.1 General Considerations……………………………………… 18-8 18.12.2 Damage Involving Engine Mounting Lugs,………………… 18-8 and Engine Mount to Fuselage Attach Fittings……… 18.13 Engine Cowling……………………………………………………….. 18-8 18.13.1 Repair of Cowling Skins……………………………………… 18-8 18.1 Structural Repair Criteria Although this section outlines repair permissible on structure of the aircraft, the decision of whether to repair or replace a major unit of structure will be influenced by such factors as time and labor available, and by a comparison of labor costs with the...
Page 188 18.1.2.2 Fuselage Repair Jigs Since repair to the fuselage is limited to repair of minor cracks and scratches, there are no jigs available for fuselage repair. In general all major damage to the fuselage has to be rated as structural due to it´s monocoque construction and return to factory is mandatory.
Page 189 or mechanism, may be considered as negligible damage. In areas of low stress intensity, cracks, deep scratches, or deep, sharp dents, which after trimming can be enclosed by a two-inch circle, can be considered negligible (i.e. wing tips). 18.2.1.2 Repairable Damage Figure 18-1.
Page 190 18.3 Wing Ribs, Description All wing ribs are constructed as glass fiber composite sandwich components. Ribs are an integral part of the wing semimonocoque. Replacement can only be accomplished by the aircraft manufacturer. 18.4 Wing Spar, Description The wing spar is constructed from glass fiber composite sandwitch material as central part of the wing structure.
Page 191 18.7 Wing Leading Edge 18.7.1 Negligible Damage Refer to Paragraph 18.2.1.1. 18.7.2 Repairable Damage Refer to Paragraph 18.2.1.2. 18.7.3 Damage Necessitating Replacement Parts If the skin of the leading edge is badly damaged, repair must be made by replacing an entire skin section. Due to the semimonocoque sandwich construction, damage of this kind always has to be rated as structural and needs to be factory repaired or replacement of the whole wing.
Page 192 18.10 Fuselage, Description The fuselage is of monocoque construction, consisting from molded fuselage halves glued together, molded bulkheads, longitudinal stringers, reinforcing channels, and skin doublers. Fuselage halves and doublers are made from carbon-fiber, bulkheads are constructed as glass-fiber sandwich components glued to the fuselage halves. 18.10.1 Negligible Damage Refer to Paragraph 18.2.1.1.
Page 193 18.12 Engine Mount, Description The mount for the aircraft engine is constructed of 4130 chrome-molybdenum steel tubing, fastened to the firewall at five points. The mounting frame provides four lugs, equipped with rubber shock mounts to hold the engine. 18.12.1 General Considerations All welding on the engine mount must be of the highest quality since the tendency of vibration is to accentuate any minor defect present and cause fatigue cracks.
Page 194 Section 19 Exterior Painting Table of Contents Page 19.1 General..……………………………………………………………….. 19-1 19.2 Paint Procedures……………………………………………………... 19-1 19.2.1 Preparing Surfaces…………………………………………… 19-1 19.2.2 Primer Application…………………………………………….. 19-1 19.2.3 Paint Finish……………………………………………………. 19-1 19.1 General The exterior painting of the aircraft consists of 2-components acrylic lacquer system from PPG, Defleet 350, paint code: 00225.
Page 195 Changed 1 Appendix 1 Wiring Diagrams Table of Contents Page Block Diagram………………………………………………………… 20-2 Wiring Diagram……………………………………………….. 20-3 Wiring Schemes…………………………………………….. 20-4 Main & Avionic Bus Wiring System…………………. 20-5 Layout scheme………………………………… 20-6 Engine Bus Wiring System…………………………... 20-7 Layout scheme………………………………… 20-8 Fuselage Wiring………………………………………. 20-9 Master Switch Wiring………………………………….
Page 196 Changed 1 Appendix-1 / Section 20-2...
Page 197 Changed 1 Appendix-1 / Section 20-3...
Page 198 Changed 1 Appendix-1 / Section 20-4...
Page 199 Changed 1 Appendix-1 / Section 20-5...
Page 200 Changed 1 Appendix-1 / Section 20-6...
Page 201 Changed 1 Appendix-1 / Section 20-7...
Page 202 Changed 1 Appendix-1 / Section 20-8...
Page 203 Changed 1 Appendix-1 / Section 20-9...
Page 204 Changed 1 Appendix-1 / Section 20-10...
Page 205 Changed 1 Appendix-1 / Section 20-11...
Page 206 Changed 1 Appendix-1 / Section 20-12...
Page 207 Changed 1 Appendix-1 / Section 20-13...
Page 208 Changed 1 Appendix-1 / Section 20-14...
Page 209 Changed 1 Appendix-1 / Section 20-15...
Page 210 Changed 1 Appendix-1 / Section 20-16...
Page 211 Changed 1 Appendix-1 / Section 20-17...
Page 212 Changed 1 Appendix-1 / Section 20-18...
Page 213 Changed 1 Appendix-1 / Section 20-19...
Page 214 Changed 1 Appendix-1 / Section 20-20...
Page 215 Changed 1 Appendix-1 / Section 20-21...
Page 216 Changed 1 Appendix-1 / Section 20-22...
Page 217 Changed 1 Appendix-1 / Section 20-23...
Page 218 Changed 1 Appendix-1 / Section 20-24...
Page 219 21-2 21.1 General Safety Directives where issued by Remos Aircraft GmbH, to ensure the safe operation of the aircraft if required. Safety Directives are issued in accordance to the applicable ASTM continued airworthiness specifiacation. Service Directives are considered as mandatory tasks in order to maintain a condition of safe operation and compliance with the applicable original ASTM design specification.
Page 220 21.2 Operational Safety Monitoring System An operational safety monitoring system is maintained by Remos Aircraft GmbH to ensure continued airworthiness of your aircraft. To receive and evaluate all safety of flight and service difficulty reports a feedback form is provided with this maintenance manual.
Page 221 Annual/100hour Inspection Checklist Condition Inspection Checklist Related to FAR 43, Appendix D Aircraft Make/Model: Remos / G-3/600 S/N: Engine Make/Model: Rotax / S/N: Date of Inspection: TT Engine: TT Airframe: Each person performing an annual or 100-hour inspection shall, before that inspection, remove or open all necessary inspection plates, access doors, fairing, and cowling.
Page 222 Each person performing an annual or 100-hour inspection shall inspect the following components of the landing gear group: 1 Pass Fail All units/for poor condition and insecurity of attachment. 2 Pass Fail Linkages, trusses, and members/for undue or excessive wear fatigue, and distortion.
Page 223 Notes and explanation of unairworthy items found: Attachment-A 22-3...
Page 224 Please use this feedback form to report any safety of flight or service difficulties to Remos Aircraft GmbH. It is important for the operational safety monitoring system and will guarantee the continued airworthiness of your aircraft. After receiving and evaluating...
Page 225 ASTM Standards and may be subject to regulatory action by the presiding aviation authority. Send to: Remos Aircraft GmbH, Franzfelde 31, D-17309 Pasewalk / Germany Phone: +49/3973/225519-0, Fax: +49/3973/225519-99 e-mail: email@remos.com, Web: www.remos.com Provide your local dealer/distributor at date of purchase.

Remos G-3 600 Maintenance Manual

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