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Remos G-3 /600 User manual

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Changed 3
Maintenance Manual
July 1st 2008
Changed 3
A
Insert latest changed pages. Destroy superseded pages.
List of Effective 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 1st 2005
Changed… 6 July 1st 2008
Total number of pages in this publication is: 225, consisting of the following:
Page
No.
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No.
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No.
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2-1 thru 2-16……….
3-1 thru 3-10.………
4-1 thru 4-7…………
5-1 thru 5-17……….
6-1 thru 6-6…………
7-1 thru 7-9…………
8-1 thru 8-4…………
9-1 thru 9-4…………
10-1 thru 10-4……...
11-1 thru 11-24…….
12-1 thru 12-15…….
13-1 thru 13-8……...
14-1 thru 14-4……...
15-1 thru 15-23…….
16-1 thru 16-20…….
18-1 thru 18-8……...
19……………………
20-1 thru 20-24…….
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22-1 thru 22-3……
23-1……………….
24-1……………….
0
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Upon receipt of the second and subsequent changes to this book, personel responsible for
maintaining this publication in current status should ascertain that all previous changes have
been received and incorporated.
Changed 1
i
Table of Contents
Section Page
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Appendix 1
Appendix 2
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 – Elevator Control System…………………………
Structures – Elevator Trim Control System…………………..
Structures – Rudder Control System………………………….
Engine…………………………………………………………….
Fuel System………………………………………………………
Propeller…………………………………………………………..
Utility Systems……………………………………………………
Instruments and Instrument System…………………………...
Electrical Systems……………………………………………….
Electronic Systems – included in Appendix 1
Structural Repair…………………………………………………
Exterior Painting…………………………………………………
Wiring Diagrams…………………………………………………
Safety Directives and Safety Monitoring System…………….
1-1
2-1
3-1
4-1
5-1
6-1
7-1
8-1
9-1
10-1
11-1
12-1
13-1
14-1
15-1
16-1
18-1
19-1
20-1
21-1
Attachments Page
A
B
C
Annual/100 hour Inspection Form…………………………….
Operational Safety Feedback Form…………………………..
Owner/Operator Responsibility Commitment Form…………
22-1
23-1
24-1
Changed 1
ii
Imprint
Published by REMOS Aircraft GmbH Flugzeugbau
Franzfelde 31
D-17309 Pasewalk/Germany
Distributed by REMOS Aircraft GmbH Flugzeugbau
All rights reserved. No part of this manual may be reproduced,
stored in a retrieval system or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording or
otherwise, without the prior permission of REMOS Aircraft.
Editior, Designer and Graphics:
Hans Fuchs
All correspondence concerning the content of this volume
should be adressed to REMOS Aircraft GmbH.
Foreword
This maintenance manual contains factory-recommended
procedures and instructions for ground handling, servicing and
maintaining Remos G-3 /600 Series aircraft. Besides servicing
as a reference for experienced mechanic, this manual also
covers step-by-step prodcedures for the less experienced man.
This book should be kept in a handy place for ready reference.
If properly used, it will better enable the mechanic to maintain
Remos G-3 /600 Series aircraft and thereby establish a
reputation for reliable service.
All information contained is based on data available at the time
of publication and is supplemented and kept current by service
letters published by Remos Aircraft Company. These are sent to
all Remos Aircraft Dealers so that they have the latest
authoritative recommendations for servicing Remos aircraft.
Therefore it is recommended that Remos owners utilize the
knowledge and experience of the factory-trained Dealer Service.
This manual is designed to meet the standard of maintenance
manuals for Light Sport Aircraft as prescribed in the ASTM
document F2483-05. According to the ASTM standard each
task does contain the type of maintenance “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.
Changed 1
iii
Common conversions and abbreviations
1 mm = 0.03937 in
1 in = 25.4 mm
Unit of length
1 ft = 0.3048 m
1 cm2= 0.155 sq inUnit of area
1 sq in = 6.4516 cm2
1 cm3= 0.06102 cu in
1 cu in = 16.3871 cm3
Unit of volume
1 gal (US) = 3.7854 l (dm3)
1 kg = 2.2046 lbUnit of mass
1 lb = 0.45359 kg
1 N = 0.224809 lbfUnit of force
1 lbf = 4.4482 N
1 bar = 1000 hPa
1 bar = 14.5037 lbf/in2 (psi)
1 lbf/in2 (psi) = 0.0689 bar
Unit of pressure
1 in HG = 33.8638 hPa
°C = (°F – 32) / 1.8Unit of temperature
°F = (°C x 1.8) + 32
1 m/s = 3.6 kph
1 ft/min = 18.288 m/s
1 m/s = 0.0555 ft/min
1 kts = 1.852 kph
1 kph = 0.53996 kts
Velocities
1 mph = 1.609 kph
1 Nm = 8.848 In.lb.
1 in.lb. = 0.113 Nm
Torques
1 ft.lb. = 1.356 Nm
Changed 1
Section 1-1
Section 1
General Description
Table of Contents Page
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.8.1
1.8.2
1.9
1.10
1.11
1.12
Aircraft Description…………………………………………………..
Aircraft Specifications…………………………………………………
Torque Values…………………………………………………………
Tire Inflation Pressures……………………………………………….
Approved Oils and Capacities……………………………………….
Engine Specifications…………………………………………………
Equipment List…………………………………………………………
Weight and Balance Information…………………………………….
Center of gravity determination………………………………
CG-Calculation………………………………………………...
Sources to Purchase Parts…………………………………………..
Disposable Replacement Parts……………………………………...
General Safety Information…………………………………………..
Reporting possible Safety of Flight Concerns During Inspection
1-1
1-1
1-2
1-3
1-3
1-4
1-5
1-6
1-6
1-6
1-8
1-8
1-9
1-10
1.1 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. Two place seating is
standard. Each aircraft is equipped with a 4-stroke, four cylinder, horizontally
opposed, water cooled Rotax 912 UL or 912 UL/S aluminum alloy engine, driving a
fixed pitch propeller.
1.2 Aircraft Specifications
Primary specifications of the aircraft, with dimensions based on gross weight, are
given in figure 1-1. If these dimensions are used for constructing a hangar or
computing clearances, remember that such factors as tire pressure or load
distributions may result in some dimensions that are somewhat different from those
listed.
Changed 1
Section 1-2
Figure 1-1.
Gross Weight………………………………………………..
Fuel Capacity………………………….…………………….
Oil Capacity………………………………………………….
Engine Model (Refer to Section 11 for Engine Data)……
Propeller (Fixed Pitch)………………………………………
Main Wheel Tires……………………………………………
Pressure……………………………………………...
Nose Wheel Tire…………………………………………….
Pressure………………………………………………
Aileron Travel
Up……………………………………………………..
Down………………………………………………….
Wing Flap Travel…………………………………………….
Rudder Travel
Right…………………………………………………..
Left…………………………………………………….
Elevator Travel
Up……………………………………………………..
Down………………………………………………….
Elevator Trim Tab Travel
Up……………………………………………………..
Down………………………………………………….
Principal Dimensions
Wing Span…………………………………………….
Length (Carbon Spinner)………………………...…
Length (Plastic or Aluminum Spinner)…………….
Vertical Stabilizer Height……………………………
Track Width..…………………………………………
Tail Span……………………………………………..
Battery Location……………………………………..
1320 lb
21 gal.
0.75 gal.
Rotax 912 Series
66.7" Tonini GT
6.00 x 4, 6-Ply Rating
29 - 34 psi
4.00 x 4, 6 Ply Rating
29 - 34 psi
20°, +/- 1°
12°, +/- 1°
0° to 40°, +/- 3°
27°, +/- 2°
27°, +/- 2°
25°, +/- 1°
19°, +/- 1°
19°, +/- 1°
19°, +/- 1°
32.3'
21.4'
21.7'
7.5'
6.9'
9.1'
Firewall
1.3 Torque Values
A Chart of recommended nut torque values is shown in figure 1-2. These torque
values are recommended for all installation procedures contained in this manual,
except where other values are stipulated. They are not to be used for checking
tightness of installed parts during service.
Figure 1-2.
M4…………………………………………………………….
M5…………………………………………………………….
M6…………………………………………………………….
M8…………………………………………………………….
M10…………………………………………………………...
4 Nm / 35 in.lb.
6 Nm / 53 in.lb.
10 Nm / 88 in.lb.
24 Nm / 212 in.lb.
35 Nm / 310 in.lb.
Changed 1
Section 1-3
Caution
DO NOT REUSE SELF-LOCKING NUTS.
1.4 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.
1.5 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. Nevertheless, general recommendations
about lubricants are shown in figure 1-3.
Caution
If engine is mainly run on AVGAS more frequent oil changes will be required. See
ROTAX Service Information SI-18-1997, latest edition. At the selection of suitable
lubricants also refer to the ROTAX Service Information SI-18-1997 latest edition.
The use of multi-grade oils is recommended. Multi-viscosity grade oils are less
sensitive to temperature variations than single-grade oils. They are suitable for use in
all seasons, ensure rapid lubrication of all engine components at cold start and multi-
viscosity oils get less fluid at higher temperatures.
Figure 1-3.
Oil specification
Motorcycle oil of a registered brand with gear additives. No aircraft engine oil should
be used.
-
-
-
-
-
Use only oil with API classification "SF" or "SG"
Due to high stresses in the reduction gears, oils with gear additives such
as high performance motorcycle oils are required.
Because of the friction clutch incorporated in the gearbox, oils with
friction modifier additives are unsuitable as this could result in a slipping
clutch during normal operation.
Heavy duty 4-stroke motorcycle oils meet all the requirements. These
oils are normally not mineral oils but semi- or full-synthetic oils.
Oils primarily for Diesel engines are generally unsuitable due to
insufficient high temperature properties and additives which favor
clutch slipping.
Changed 1
Section 1-4
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……………………………………
Temperate………………………………..
Arctic………………………………………
SAE 20W-50, SAE 20W-40
SAE 15W-50, SAE 15W-40
SAE 10W-40
SAE 5W-50, SAE 5W-40
SAE 20W-50, SAE 20W-40
SAE 15W-50, SAE 15W-40
SAE 10W-40
SAE 5W-50, SAE 5W-40
SAE 10W-40
SAE 5W-50, SAE 5W-40
1.6 Engine Specifications
The ROTAX 912 Series engines are 4-stroke, 4 cylinder horizontally opposed, spark
ignition engines, featuring one central camshaft with push rods – OHV. Cylinder
heads are liquid cooled. Lubrication system is a dry sump forced type. It is equipped
with dual breakerless capacitor discharge ignition and two constant velocity
carburetors. Prop drive is via reduction gear with integrated shock absorber and
overload clutch. Specific engine datas are given in figure 1-4.
Figure 1-4.
Description
Dimensions
Bore………………………………………………….
Stroke………………………………………………..
Displacement……………………………………….
Compression ratio……………………………….....
Weight (without exhaust, radiator, air intake System)….
Speed
Takeoff speed………………………………………
Continuos speed (max.)…………………………...
Idle speed (approx.)………………………………..
Gear Ratio…………………………………………………..
Performance
Takeoff performance……………………………….
Continuos performance…………………………….
Acceleration
912 UL
3.13 in
2.40 in
73.9 in3
9.0 : 1
132 lb
5800 rpm
5500 rpm
1700 rpm
2.27 : 1
80 hp
77 hp
912 UL/S
3.31 in
2.40 in
82.5 in3
10.5 : 1
134 lb
5800 rpm
5500 rpm
1700 rpm
2.43 :1
100 hp
92 hp
Changed 1
Section 1-5
Max. negative "g" for 5 seconds……………………
Oil Pressure
Max. for short period at cold start…………………
Min. (below 3500 rpm)……………………………..
Normal (above 3500 rpm)…………………………
Deviation from Bank Angle max………………………….
Oil Temperature
Max…………………………………………………..
Min…………………………………………………...
Normal……………………………………………….
Cylinder Head Temperature
Max. (observation at hottest cylinder, #2 or #3)…
Normal……………………………………………….
Engine Start, Operating Temperature
Max…………………………………………………..
Min……………………………………………………
Fuel Pressure
Max…………………………………………………..
Min…………………………………………………...
Electric Starter………………………………………………
Generator……………………………………………………
-0.5 g
100 psi
12 psi
29 - 73 psi
40°
285° F
120° F
190-230° F
300° F
167-230° F
120° F
-13° F
5.8 psi
2.2 psi
12V, 0.6 kw
12V, 20A
- 0.5 g
100 psi
12 psi
29 - 73 psi
40°
285° F
120° F
190-230° F
300° F
167-230°F
120° F
-13° F
5.8 psi
2.2 psi
12V, 0.6 kw
12V, 20A
1.7 Equipment List
In figure 1-5 a list of factory installed equipment is provided. Additional installed
equipment and alterations have to be considered when performing weight and
balance calculation. If a ballistic recovery system is installed from the factory, this is
already included in the factory weight and balance calculation form.
Figure 1-5.
Factory Installed Equipment
Airspeed Indicator, Altimeter, Vertical speed indicator, Compass, Slip indicator
RPM gauge (Rotax Flydat)
Oil pressure gauge (Rotax Flydat)
Oil temperature gauge (Rotax Flydat)
CHT gauge (Rotax Flydat)
Exhaust gas temperature gauge (Rotax Flydat)
Manifold temperature
Electric fuel gauge
Position lights
ACL (Anti Collision Light)
Master-, avionics and engine kill (ignition) switch
Electrical system including circuit breakers
4-Point safety belts (pilot and passenger)
Ballistic recovery system (optional factory equipment)