GROB-WERKE GMBH & CO.

KG
Unternehmensbereich
B u r k h a r t G r o b Flugzeugbau
8939 Mattsiea
A m Flugplatz
Telefon 08268/411
Telex 539 623

MAINTENANCE MANUAL
GROB G 103

This Maintenance Manual is for U. S , r e g i s t e r e d

gliders.
Registration: . .. ,. . . . , . . . F a c t o r y S e r i a l No. : ...
Owner:

Published September 1981

Approval of translation h a s been dons by b e s t knowle
and judgement - i n any c a s e the original t e x t in G e r n
language i s authoritative.
1.
1. MAINTENACJCE
.; , ,
MANUAL GROB G 1 0 3
,...
--
1
-.,..
L o g of r e v i s i o n s
.~

signature

! 5

1,a
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[Modification
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f / June i
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iI 5, 6, 7, i from serial
i 8 , 1 2 , 1 3 , ! n o . 3730
'1
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i 1982
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ii 2114,,2125 , i1 (AM 315-12) !
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3 : 1 , l a , 1 1 , j Modification 1 Febr. 1
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; 12,13 /from serial ! i 1984 ;
/ n o . 3839 1 I
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A l l handbooks f o r GROB G can be ordered at:

j' - B u r k h a r t G r o b Inc.
1070 Navajo D r i v e
1 Bluffton, OH 45817 / USA (419) 358-901 5
- G r o b - W e r k e GmbH & Go. KG
U n t e r n e h m e n s b e r e i c h B u r k h a r t Gr ob F l u g z e u g b a u
I F l u g p l a t z Mindelheim- M a t t s i e s
i1 8939 M a t t s i e s , West G e r m a n y
(08268) 411

i Febr. 1,1984
i
MAINTENANCE MANUAL GROB G 103 1a

Pages included:

F e b r . 1 , 84 17th march 82
Febr . 1 , 8 4 17th march 82
Sept. 81 17th march 82
Sept. 81 17th march 82
Sept. 81 17th march 82
June 82 17th march 82
June 82 17th march 82
June 82 17th march 82
June 82
June 82
Sept. 81
Sept. 81
Febr. 1 , 84
F e b r . 1, 84
F e b r . 1 , 84
June 82
June 82
Sept. 81
Sept. 81
Sept. 81
Sept. 81
Sept. 81
June 82
June 82
Sept. 81
Sept. 81
Sept. 81

Febr. 1 , 1 9 8 4
 MAINTENANCE MANUAL GROB GI03 2
-
Contents
Log of r e v i s i o n s
Contents
I. T e c h n i c a l 'Data
11. D e s c r i p t i o n of c o m p o n e n t s
1 Control Linkages
r D r a w i n g of f u s e l a g e c o n t r o l s
D r a w i n g of r u d d e r c o n t r o l
Drawing of wing c o n t r o l s
2 I n s t a l l a t i o n of Radio 10
3 Installation of Oxygen 10
4 I n s t r u m e n t s s p e c i f i c a t i o n s f o r b a s i c equip- 10
5 P r e s s u r e tubing a n d connections to m%t
the instruments 11
111. Rigging C a t a
IV. Rigging and d e r i g g i n g
1 Rigging
2 Derigging
#
3 Transport
V. Maintenance
1 Maintenance of g l i d e r ;..
? 2 Maintenance of b r a k e s y s t e m

VI. Weight a n d M o m e n t s of t h e c o n t r o l
surfaces
VII. checks
1 Daily c h e e k s .
2 Checks i n specific c a s e s
3 Regular service

S e p t e m b e r 1981
 MAINTENANCE MANUAL G R O B GI03
-
2a

VIII. Lubrications
IX. General care
X. A i r w o r t h i n e s s limitations
1 Annual inspection checklist
7' 2 Inspection p r o c e d u r e f o r i n c r e a s e
of s e r v i c e t i m e
3 Components with a limited life t i m e

II
I,

(LBA approved pages: 26 through 3 3 )

S e p t e m b e r 1981
MAINTENANCE MANUAL GROB G103 3

b
F
--
€803
17,s m
17,8 m'
67.4 ft.
181.6 aq. ft.
17,l

span baR -- 3,65111 12 tt.

Chord inner

Area
outer
11
ta
FaR
-- 0.- rn .tMft.
.
0,10511 34ft.
1, 14m' 1k27 sq. f t .
% 01 Wing area 6,40 %

Length 1 -8,.18rn26 811.

Width of cockpit
Height of cdckpit
b
h --
-0,71111 28indres
l,02m 40 inches
Helghl of taliplane
Surlace arm ca.
h
F - 1, ,55 m 5. 0 9 tt.
13 m' 139.94sq. ft.

Heigiht
Ared
Aspect Ratio
Chord bottom
top

% 01 Fin
Area

September 1981
 1
A m F -0,64'n2 6,89 a q f t
Chord inner ti =0,245 a O,8O'ft
Trimm tab
Span
Area
Chord Inner
. . . ~ - ~-
urbfalar (Qmb 81.torn). .. . .. .,
-~

Area (Each) F BK -- 1
O,W ms 5.425 sq.. it.,
.
'..
.

1
,

Span b 1,4 m 4.59 ft.

Height h -0, 18 m- 7. 1 inches ,..
1

Empty weight ca. 380 kg 8 3 8 ibs.

Load Maxlmum 200 kg 44 i lba.
1. Seat 110 kg 242 lbs.
2. Seat 110kg 242lba
B=kx=ge 10 kg 22 ibs.
Load Minimum (1. Seat) 70 kg 154 lbs.
Maximum Flying Weight 580. kg 1279 ibs.
Load% of Flying Weight . 36 %
Wing Loading 25, 3-32, 6 kg/m 2 5. 18-6. 68bs.lsq. ft.

Maximum welght of non-lifting parls 4 0 0 kg 882 ibs.

16th june 1982

 II. D..ulpUon ol Camqonmb

The control of the TWIN 11 is designed as a push-rod system. The

stick, bellcranks and horns are made from s t e e l t u b s o r
aluminium, t h e pushrods a r e made of alumi-
---.
--.
\
I
Elwator
niun tubing. I

The control stick force is transfered from the control stick via the stick
mounting framecl to the eievator puahrod. The two control sticks are
firmly connected. The rear control atlck is deta&able and held in
place by a butflynutdhree elevator pushrod leads from the
rear sllck to the elevator horn in the aide fin. A connection rod with
snap fastener drlves the horn in the elevator. All the components
in the fuselage may be dismantled. The elevator horn Is laminated into
the elevator. Stops for the elevator are rltuated on both stick moun-
ting frames under the seatr.

The lateral control force la tmnakred from the control stick via a
short connection rod to the aileron control bellcrank on the side of
the fuselage. .!
I
T aileron control bellcranks for both control sticks are
rigidly connected by means of 2pushrod. Pushrods lead from the rear
crank via an I n t e n d l a t e crank at the wheel box to the lower con-
nection to the linkage ammbly in the bottom of the fuselage. The
aileron control connection and the ~urhrodsin the wino are driven
via t h e uppercrank o f t h e l i n k a g e a&enbly.
The outboard allemn control differential lever in the wing drives the
aileron directly vla a short pushrod. All components of the aileron
control system in the fuselage may b% dismantled. The aileron control
differential lever and the pushrod in the wlng may only be dismantled
through an opening made in the QFK skin. Stops for the aileron
linkage are present on both control sticks.
 M A I N T ~ N A N C E MANUAL GROB ~ 1 0 3 8

Rudder Linkage0
Control cables lead from the front pedal mounting .
which can be adjusted in steps. The cables lie on
the inside of the pedal8 and a r e routed to the bell
crank o f t h e r e a r p e d a l u n i f l h e 'complete
rudder linkage system' may be dismantled. The
stops for the rudder and the bellcranlc'are mounted
n e a r t h e r e a r p e d a l mounting. 1 '
I

1 6 t h june 1982
 I .-
MAINTENANCE MANUAL GROB G 103 8 ?
 I

MAINTENANCE MANUAL G R O B GI03 ' 8

16th june 1982

91
Wing controls: Ailerons
and Air brakes
 MAINTENANCE MANUAL G R O B G103 10

The front instrument panel may be obtalned in three layouts.and can

accommodate a rectangular Instrument (80 x 80 mm or 148 x 47 mm)
aa well aa 80 mm dlametor Instruments. The Internal loudspeaker
should be mounted on the rear instrument panel. 'Swan neck'
microphone booms may be mounted to the pilots right on the canopy
frame. The shelf under the rear control linkage complex is prepared
for fixlng a battery. Drawlngs for the Installation of the radio unit can
be obtained on request.

An Oxygen cylinder msy be mounted behlnd the rear seat. Drawings

for the lnstallatlon of the Oxygen equipment can be obtained on
request.

11.4. I n s t r u m e n t s specifications f o r b a s i c equipment

A i r s p e e d Indicator

The original certification was carried out using 2 Winter 6FMS4-2

A i r s p e e d indicators.
A similiar FAA approved airspeed indicator to meet TSO C 2 reading
to 3 W kmlh (162 kts. 187 mph) may be used. o orexample
P Z L PR-400 S).
Altimeter
The original certification was carried out using a Winter 4FGH 10 and
a Winter 4 HM 6 .
A similiar FAA approved altimeter to meet TSO C 10 with a ra ge to
35.000feet may be used. ( F o r example PZL W -12 SY
Magnetic C o m p a s s (compensated inside the g l i d e r )
The o r i g i n a l certification w a s c a r r i e d out using
a Airpath C 2 3 0 0 .
A s i m i l a r FAA approved magnetic c o m p a s s to
m e e t TSO C 7 m a y be used.
( F o r example P Z L BS-1)
MAINTENANCE MANUAL GROB G103 11
!' r
I ..".-
1

11.5 R r u n h r # n g m d ~ L o U n I r * t r p r m S I

1 ~6honrnees;r (altimeter)
2 Fahrtmaawr (alr speed indicator)
3 Varlometer (variometer)
4 Kompensationsdiise (total energy tube)
5 p i t o t - s t a t i c - ~ o h r (pitot static tube)
6 Statischer Druck (static pressure) farblas (colourless)
7 Staudrudc (pitot pressure) griin (green)
8 Diise (Totelaneray) rot (red)
9 Ausgleichsflas&e (flask) biau (blue)
 0
Adjustment Reference Line Value
F Wing - Angle between the centre line of the wing
; Incidence angle
~-
and the longitudinal axis of the fuselage 2" 30'
ID
Wing - Distance of line joining the wing tips
"
@J

Sweep forward from the reference line 0

Wing - Angle between the top surface of

Dihedral the wing and horizontal 3.5" i
--- -- --- .

Tailplane - Angle between the chord of the tailplane

Incidence angle and the longitudinal axis of the fuselage 0
Reference line Front'of the wing'at the root rib
QE 2980
--
Control defections Upwards (right) Downwards (left) Measurem
Value Tolerance Value Tolerance contre
---.- -... , .
Aileron Port 90 f. 10 50 k 8 iz-
Aileron Starboard 90 2 10 50 t8 208 mr
Elevator
.~
95 '8 74 5 6 240 m
Rudder 233 f 10 233 -+ 10 450 mm
- ~-
Retease Hook Backrelease load 0.5 to 1 kg (1.1 to 2.2 lbs)
Maximum pull to release 7 kg (15.4 lbs)

I T r i m m tab 45 t 5
- 45 +
- 5 60 m

1 (elevator neutral)
F e b r . 1,1984
 MAINTENANCE MANUAL GROB E l 0 3 14
4

IV. nmlng drmhl

The fuselage must be held firmly in a horizontal posltlon when rigg~ng'

it Is recommended to use a fuselage stand or the trailer fittings are
used.
I
The glider can be rigged by 4 people.

Unlock the 4 main wing fittings in the fuselage. Unlock

the a i r b r a k e a on the wings. Guide the right wing into
the fuselage. T h e safety catches on the fuselage fittings
should now be r e l e a s e d , and on gently moving the wing
f o r w a r d and aft it can be h e a r d to snap into place. Next
guide the left wing into the fuselage. Move the wing
tips up o r down so that the pin on the end of the s p a r
stub i s lined up with the appropriate hole in t h e oppo-
s i t e wing root and slide into place. Next r e l e a s e the
safety catches on the left hand fuselage fitting and b y
gently moving the wing t o and f r o they too can be made
to snap into place.

T o s e c u r e the fuselage-wing linkage in the closed

position the safety nut (1 ) m u s t be turned into the
threaded socket (21 s o that the socket i s pull in-
boards against t h e r e d ring which is held by the
guide pin (3)

16th june 1962

 I
!
1 I' I I
I

MAINTENANCE MANUAL G R O B GI03 I

15, I

!
L a geolfnet

' ,

By moving the wings f o r w a r d and aft strongly while ,

,tdrni& the s'afety nut into the socket this linkage
, can be s e c u r e d tight enough (4). The gLide pin m u s t
,not t o u c h t h e end of the dot i n the socket.

,Check: The socket m u s t cover the r e d ring.

T h e safety nuts m u s t be turned hand-tight.
I
I
.-
In the clo.&but unsured position ( b ) the wing bolt cannot be
pulled out of.the lining.
,
T h e connecting r o d s can be connected by meank
of the quick lock f a s t e n e r s through the i n s p e c -
tion opening.
Having engaged the quick locks check that the
safety pin cannot be moved without presaing it
down. If it cannot be slid without p r e s s i n g down
when the controls a r e p r o p e r l y connected.
MAINTENANCE MANUAL G R O B GI03 16

3. Tailplane
Before aeaembly i o commenced the front cover
muet be opened and the rotating wing bolt pul-
led out to the limit. It i s important to ensure,
that the targer opening of the conical crillings
in the inner rings of the horizontal stabilizer
spar bearing fall to the rear. The tailplane can
be poeitioned by standing behind the rudder.
The tailplane can be rested on top of the fin
with the elevator angled upwards so that the
quick lock (System Hotellier) on the trimm
tab push rod can be attached to the ball on
the trimm tab horn and the quick lock 'System
Grob) on the elevator push rod can be attached
to the bearing on the elevator horn. The front
of the tailplane can then be lowered and pushed
back onto the three pins. It i s then necessary
to tighten the wing bolt clockwise to secure
the tailplane. The assembly ie complete when
the wing 'bolt ie eufficiently tight that there ia
no play in any direction. The cover providee a
safety measure a s it can only be attached with
the wing bolt horizontal. If necessary the wing
bolt h a s to be turned a 114 turn to suit. Derig-
ging i s carried out in the opposite o r d e r and
the wing bolt i s turned anticlockwicre and pulled
fully out.
To control the correct mouuting of the horizon-
tal stabilizer it 1s important to ensure that the
peako of the mark-arrows a t fin and elevator
tabs face each other.

September 1981
 MAINTENANCE MANUAL G R O B GI03 17

1. Chedc that tha 4 main wing fittings ere locked.

2. Chedc that aileron and brake quid-actions locks are properly
located on the knobs.
3. Ensure that the tow hook is functioning correctly.
4. Test the operation of the wheelbrake and the tire pressure

5. Chedc that the taliplane is securely seated and that the elevator
push-rod is connects4 control the 4 markings.
6. Rudder movement.

*V. 2. D.rtgghIg
Derigglng Is carried out in the opposlta order end in thiacase i t doe
not matter whldr wing is removed flrst. Excessive fore and aft rocking
of the wing tlps should k evoided.
IV. 3 rnnrport
We recommend the use of a closed tralier for transporting the gilder.
The parts must be carefully supported and secured so they cannot
slide. - .
1. Fuselage
A fuselage trolley 'moulded to the shape of the fuselago and
posithned in front of the msln wheel. The minimum length of the
trolley should be 400 mm and it can be attached to the wing fittings
if required. ha tall skld should be ~ecuredso that it cannot slide
oidewap.
2 Wings
The minimum length for the spar support should be 200 mrn and
should start at the face of the root rib. The mounting must be
padded well wlth foam rubber or felt.
The mounting under the aileron Inboard end should be a shaped
mounting biodc with a minlmum length of 3M3 mm and he~ghtof
400 mm. The mounting must be padded with felt.
3 Taliplane
E~ther horizontal on padded supports wlth the upper surface
downwards and se~uredwlth straps or vertical supported on the
leading edge in shaped mounting blocks.
Profile drawlngs are avallable for the manufacturg of fuselage, wing
S~^C,A~..
and tyighape fittings.
 MAINTENANCE MANUAL G R O B GI03 18

V. Maintenance

The entire eurface Of the glider is coated wlth weather resistant while
polyester gelcoat.
The greatest care should be taken in maintaining the fibre @ass
surface of the glider. Luke warm water should be w d to wash off
dust, grease, dead flies and other dirty m u k a More resistant dirt
should be removed by using a mild cleaning agent. Only special siii-
con-free preparatlons should be used In rnalntnlning the painted sur-
-
faces. (1 2-Spezielreiniger D 2. Fa. W. Sauer and Co.,5060 Bensberg
or Reinlgungspolish Fa. Lesonai).

Although very reslstnnt the gllder should be protected as much as

possible again81 rain and dampness. Water that has caeped in should
be dealt wlth by storing the gilder In a dry place, frequently turning
over the dismantled parts.
The moal effectiveway to clean the canopy is to use a special perspex
cieener but If necesary luke warm water can be used. A soft, clean
cloth or chamole.-lealher should be employed to wlpe the canopy
down. Never rub pempsx with anything dry.
The Safety harness should be regularly checked for damage and
general wear. The metal parts of the harness should be frequently
chedted for corrorlon.
3 Because of Ita position, the wlnch launch hook la susceptible to getting
very grimy and muddy. it must therefore be frequently inspected for
damage, cleaned and greased. When the seatwell is removed the
hook can easily be tnken out. Remove the connffiting wire from the
, lever and take out the retaining screws. For recondltionin~,the tow
hook should be sent wlth the record card to the tow hook menufac-
turer, Tost. For further detail8 the manutacturera manuals should be
consulted.
The cables and pulley for the nose and belly hooks should be chedced
for weer during the yearly inspection.
The main wheel lyre presaure should be kept at 2.5 to 2.8 bar
nosewheel and tailwheel 2 , 5 bar
MAINTENANCE MANUAL G R O B GI03 19

V. 2. Maintenance of B r a k e s y s t e m '
T e wheelbrake of the I'TWIN i s a d i s k brake.
~ i s dismantling
n the Mainwheel f o r cleaning o r
g r e a s i n g purposes, o r changing the t i r e , u n s c r e w
P o l y - s t o p n u t s M8 and r e m o v e wheelaxle to the
left. Then r e m o v e distance pipe f p 42x2) to the
right. 'distance bush = D i s t a n z b ~ c h s e ) .Remove
wheel downwards, clean a l l p a r t s and g r e a s e be-
f o r a s s e m b l e again.

Cha.nging of b r a k e s h o e s
a ) Remove the wheelcover.
b) Loosen 1/4 inch s c r e w s (spanner s i z e 11 m m )
to take out b r a k e . Do not retnove b r a k e p i p o r
you have to bleed again.
;P,
c ) Take off the two p a r t s , on witch t h e 'brakelining
a r e riveted on.
d ) Mount new brakelining with rivets, a s s e m b l e in
reverse order.

Bleeding of b r a k e s y s t e m
a ) Mount t r a n s p a r e n t plasticpipe on bleedingscrew
put o t h e r end of pipe in a container with b r a k e -
fluid.
b) Loosen bleading s c r e w , when b r a k e via l w v e r
andbrakezylinder pushes brakefluid trough the
brake.
c ) Bleeding i s complete when no m o r e a i r b u b b l e s
can b e s e e n in t r a n s p a r e n t p l a s t i c pipe.
September 198 1
 MAINTENANCE MANUAL G R O B GI03 20

Remarks:

I The ATE brakefluid DOT 3 (ambercoloured) i s

I available in every shop for car parts. Standardi-
zed within Europe.
The master brake cylinder with the brake fluid
reservoir is located under the baggage compart-
ment.
The marks for the lowest andhighest level of the
hydraulic brake fluid have to be observed.

September 1981
 MAINTENANCE MANUAL GROB 0103 21

Vl. ~ r d ~ o s m e b . ~

The momenta of the control w&cm muat not exceed the lollowlng
ValUee:

Elevator
(t trirnm tab)33,5 k Cm"*(+I2$
,$ 4,'5, kg+ 15%
\

. Trirnrn tab 1.5 kg un 2 15% O,5f kg ?: 151.

Rudder 20, 0 kg cm -+ 10% 5; 0 kg + 10%
Aileron

To determine Me moment M -
Ths moments mu@ be m w m d *lu, the control rutlace8 removed.
R r Vw wrkcr W i d be mounted
.t the hhgb llnr with the mlnbnum lrlotkn potls)bl? The force P c m
be mupund, lor emmple, using a Mtrr rcrk. If thme valuer are
eaceeded Me mur bJ.na should b. l n o r r d . Before orrwlng out
repan which for exampla tnwlvo charging the maw balance on a
surface the mrnufrcturer or his repair agent must be censulled.

( 1 kg = 2,20 lbs, 1 kgcn = 7,23'ft.lbs

 MAINXENANCE MANUAL GROB, G103 : , 22
I 1 ' I
1 ' , I

I
VII. 1. Daily checks , I
/ 1
I, .
I

\ Dally checkq end chedcs'before ?unch: See ~lighk~ ~ n d b o IV-2.

ok

--
-
1, I'
I Alter a heavy ianding:
he& the ihdercarriage mechanism under the rear seat, die$ ihe
' undercarriage mountings in ,the wheel check the spar end root rib
for white p a t a m In the glassfibre reinforced plastica (GFK).
Chedc the wing fltilngs In the fuselage end the pins in the root rib.
Check.all mounts of control surfaces.
A b r a Oroqd loop:
: Check the undercarrla e mounting, check the rhdder controls rods
8
and bellcranks behin the wheel well.
Chsdc the OFK tube at the baae of the fin.
I
C h ~ the
k wi"g fitting8 i n the uselage and the connecting pins In the
root rib.
~ h d c kthe tail plane suspensions.
vll. 3, ' ~ . g u h-MIX
r

The following schedule of service should be carried out every 1W hours

S or et the annual Inspection, which e v e r o c c u r s f l r e t .
I
-. 1 1. The entire glider should be checked for cracks, holes end bumps.

2. All fltiings should be inspected for satisfactory condition (play

scores end corrosion).
3. All metal parts should be examined for corrosion, cracks, defor- '
mation and If necessary reconditioned end freshly protected.
4. Chedc that there Is no play In the wing and tallplane to fuselage
fittlnga. i

5. The control linkages (Bearings, stops, fltflngs, hinges end control

cables) should be Inspected and replaced if there ia evidence of
bending or corroslon.

16th June 1982

MAINTENANCE MANUAL GROB GI03 23

6. The controls including the brakes should be submitted to a func-

tional test and the control deflections checked.
7. H the controls do not move free throughout their range, search
for the cause and correct.
8. The 3 wheels and b r a k e should b e
checked to be in good condition.
9. The two hooks should be treated in accordance with thelr
appropriate maintenance manual.
10. Check the pltot for the AS1 is clear and that the tublng to all
instruments is in good condition and free of leaks or kinks.
11. The condition and calibration of all Instruments should be checked
and any other equipment Inspected.
12. Equipment and instruments should be checked against the equip-
ment list.
13. The wing bending mode h a s to be e s t a
lished and checked with t h e figure stated
k-
a t the approval r e p o r t ( S t ~ c k ~ r ~ f b e r i c h t )
The glider h a s to be supported a t main-
wheel and tail. The t i r e p r e s s u r e m u s t
be 2 , 5 - 2 , 8 b a r .
14. After r e p a i r o r change of equipment, the weight
table should be updated with the new empty weight
and c e n t e r of G r a v i t y by weighing o r cklculation.
After extended s t o r a g e check accordingly to r e g u l a r
s e r v i c e poa. 1 to 11 and inspect f o r evidence of rodents
and b i r d n e s s . .

S e p t e m b e r 1981
 - .-.
-
.
MAINTENANCE MANUAL GROB GI03 24
--- .- -. -- .-

VIII. Lubrication

Ball B e a r i n g s
All b e a r i n g s installed a r e sealed w i t h a permanent
g r e a s e filling. Greasing o f b e a r i n g s i s t h e r e f o r e
unnecessary.

' Sliding B e a r i n g s
All slide bearings installed o n t h e fixed control
linkages do not r e q u i r e servicing o r greasing.
However, t h e push rod b e a r i n g s i n t h e root
r i b and on the tailplane mounting should be
cleaned w i t h pert01 and r e g r e a s e d w h b d i r t y .
T h e pins and b u s h e s o n the wing f i t t i n g s should
b e r e g r e a s e d w h e n n e c e s s a r y during rigging.

T h e pins on t h e tailplane fittings and t h e s c r e w

thread should b e lubricated periodically. T h e hinge
and catch of t h e c o v e r should be occassionally oiled.
D i r t y r e l e a s e h o o k s a r e b e s t cleaned using a b r u s h
and c o m p r e s s e d a i r w h i l s t operating t h e m e c h a n i s m .
T h e b e l l y hook i s a c c e s s i b l e f r o m inside and can
b e lubricated w i t h Sprayoil o r s i m i l a r .

S e p t e m b e r 1981
 MAINTENANCE MANUAL G R O B GI03 25

A s f a r a s possible t h e glider should be protected f r o m

dampness. All the m e t a l p a r t s of the g l i d e r , with the
exception of the wing and tailplane fittings a r e protecte
against damp. However, this will not prevent corrosiol
during extended exposure to m o i s t u r e . Following any
flights in rain any w a t e r which h a s e n t e r e d the glider
should be d r i e d up and the e x t e r i o r s u r f a c e s d r i e d with
a c h a m o i s leather. Polished m e t a l p a r t s should be
r e g r e a s e d . Beware of condensation.

All structural parts of GFK glider dhould have white surfaces to avoid
them heating up In sunlight.

The Gelcoat surface layer Is very resistant and can therefore be

cleaned using a mlld detergent. lngralned dlrt such as grease and
dead ll~ea,are beat removed with a SILICONE-FREE pollsh (1 Z Spe-
zlal-Reinlger or "Reln~ungspoilsh", Fa. Lesonal, Stuttgart).Sticky tape
used for sealing the wing and tallplane Joints may be removed uelng
thinners of Petrol (Bewere thinners may remove the markings).

The canopy should only be cleaned uslng a soft clean cloth or sponge
and a mlld soap solutlon. It should be rinsed wlth clean water and
dried wlth a chamolr leather. "Plexipol' Is a suitable polish. Never rub
perspex wlth anything dry.

September 1981
 MAINTENANCE MANUAL G R O B G 1 0 3 ZC

X . A i r w o r t h i n e s s Limitations

T h i s A i r w o r t h i n e s s Limitations section i s
FAA approved f o r U. S. r e g i s t e r e d g l i d e r s
in a c c o r d a n c e with the provisions of 14 CFR
section 21. 29. In addition, t h i s section i s
r e q u i r e d by FAA T y p e Certificate Data
Sheet No. G 39 E U and it specifies m a i n -
tenance r e q u i r e d under 14 C F R s e c t i o n s
43. 1 6 and 91. 163 unles an a l t e r n a t i c e p r o -
g r a m m h a s been FAA approved.

LBA approved on : . . . . . . 17th . .

. . . m. .a.r .c .h. .1982
.. . .

T h e following section specifies r e q u i r e m e n t s

f o r the instructions f o r continued a i r w o r t h i -
ne88.

17 t h march 1982
 MAINTENANCE MANUAL GROB G I 0 3 27

XI. 1 Annual Inspection Checklist

B
WING

:--I ;h
:. C r a c k s in shell.
Root r i b
.. .

') . . ~
Spar Etub
.- Drain holes
F i t t i n g s a t root r i b
..
Aileron b e a r i n g s
Aileron d r i v e
Divebrake d r i v e
-
TAILPLANE
Finish
- Shell
-
C r a c k s in ahell
-- Drain holes
- Bushes for mounting
.-
Elevator bearings
 MAINTENANCE MANUAL GROB G I 0 3 28

FUSELAGE
T-l
Finish
Shell
C r a c k s in s h e l l
Drain holes
Rudder bearings
Bushes f o r wing root pins
Stabilizer mounting
Cockpits
Seats
Frames
Canopie s
Canopy m e c h a n i s m
Canopy e m e r g e n c y r e l e a s e
Canopy window

Control stick
Elevator drive
Divebrake d r i v e
Aileron d r i v e
Aileron connectors
Divebrake connectors
T r i m control

Pedals
P e d a l adjustment
Steering- cables
.. E a r t h connections
I
-, i Cockpit ventilation
I B a c k r e s t adjustment
-4
I H e a d r e s t adjustment
-- -

17 th march 1982
 M a i n t e n a n c e H;HtBhook G R O B G 103 29

Control surfaces (Aileron, Elevator, Rudder)

R u d d e r ventilation
Rudder drive
?--1
, Connecting m e a n s
I
1 -4
! LANDING GEAR (Mainwheel, T a i l w h e e l , Nosewheel)
;-/
Undercarriage and axle

~
I-
I
a Tyre
P r e a e t load a t folding s t r u t
1 Bearings and joints
I~Ii
~ r i v . rod
i :
Connecting m e a n s
.-
I Locking
1

Overcenter
wheel brake system
u
1 I EQUIPMENT
M i n i m u m In a t r u m e n t a t i o n
1 -j Additional I d s t r u m e n t a t i o n
Operating range
--i
: Limit m a r k s
Oxygen b o t t l e s
i Working of I n s t r u m e n t a t i o n
; Tubing
T o t a l e n e r g y unit
-. ,
pitot system leakfree
Static r y e t e m l e a k f r e e
T. E. system leakfree
k-
i -'
Electrical cables
B a t t e r y a i d fitting
i--
[--I Radio
Antenna
I
I....-', C o m p a s s deviation l i s t
17 t h rnorch 1982
 MAINTENANCE MANUAL GROB GI03 30

Seat belt h a r n e s s
C. G. r e l e a s e
Nose r e l e a s e
I- Weight and balance plan
Data p l a c a r d
b Cockpit p l a c a r d s
5 P l a c a r d with s e r i a l number
I -- Cockpit pocket
)i'
,.. Baggage compirrtment c o v e r
.-
ADJUSTMENT
r:Wings
'

and horizontal t a i l
-I P l a y a t root r i b s
f-
; , Z e r o setting of control s u r f a c e s
1
~- Control surfaces.deflectiona
Dive b r a k e deflection
I
.--
, Wheel b r a k e
T r i m control
i. -. Nose r e l e a s e function
I I C . G. r e l e a s e function
.
8 Automatic C. G. r e l e a s e
:,--, Aileron differentiation

P r o c e d u r e s and c r i t e r i a f o r performing t h i s
inspection a r e contained i n Section VII. 3 , page
2 2 of this manual.

17 t h morcn 1982
 -
MAINTENANCE MANUAL G R O B GI03 31

X I . 2. Inapection P r o c e d u r e F ~ YI n c r e a s e Of
Service Time

- - - G- -e-n-e-r-a-l -
1.

The r e s u l t s of fatigue t e s t s of wingspar section

have demonstrated r e c e n t l y that the s e r v i c e
t i m e of F R P g l i d e r s m a y be extended to 6000
h o u r s , if for e a c h individual glider (in addition
to the obligatory annual inspections) the a i r -
w o r t h i n e s s i s d e m o n s t r a t e d according to a spe-
c i a l m u l t i - s t e p inspection p r o g r a m particularly
with r e g a r d to the s e r v i c e life.

When the glider h a s r e a c h e d a s e r b i c e t i m e of

3000 h o u r s , an inspection m u s t be done in acco
dance with the inspection p r o g r a m mentioned
under point 3. If the r e s u l t s of this inspection
a r e positive o r if any defects found have been
duly r e p a i r e d , the s e r v i c e t i m e of the glider i s
extended b y another 1000 h o u r s to a total of
4000 h o u r s ( f i r s t step)
The above inspection p r o g r a m m u s t be repeatel
when the glider h a s r e a c h e d a s e r v i c e t i m e of
4000 hours. If the r e s u l t s of this inspection arc
positive o r i f a n y d e f e c t s found have been duly
r e p a i r e d , the s e r v i c e t i m e of the glider i s e x -
tended to 5000 h o u r s (second step).
When the glider h a s r e a c h e d a s e r v i c e t i m e of
5000 h o u r s , the above inspection p r o g r a m agai
m u s t be repeated. If the r e s u l t s of the inspec-
tion a r e still positive o r if any defects found
have been duly r e p a i r e d , the s e r v i c e t i m e m a y
b e extended to a total o/f,,bQO@ours (third step)
A

17 th march 1982
 -
MAINTENANCE MANUAL G R O B GI03 32
--- -
F o r a possible s e r v i c e t i m e exceeding 6000 h o u r s
p r o c e d u r e s will be evaluated in the future.
3. In each c a s e the l a t e s t i s s u e of the inspection
p r o g r a m , which will be updated according to
incoming inspection r e s u l t s , h a s to' be o r d e r e d
f r o m the manufacturer.

4. T h e inspection m u s t only be done by the manu.

- f a c t u r e r o r by a licensed r e p a i r station o r
l!-! inspector.
5. T h e r e s u l t s of the inspections have to be r e -
corded in an inspection t e s t r e p o r t wherein
comments a r e r e q u i r e d f o r each inspection in-
struction. If the inspections a r e done outside
the m a n u f a c t u r e r ' s facilities, a copy of the
r e c o r d s must be sent to the m a n u f a c t u r e r for
h i s evaluation and information.
6. The annual inspection i s not affected by this
inspection p r o g r a m m .

17 th march 1982
 --
MA1 NTENANCE MANUAL G R O B G 103 33

XI.3. Components with a limited life t i m e

a ) Tow hookr

The E 7 5 a n d the G 73 Toat hooks a r e l i m i t e d

to 36 months a f t e r installation o r 2000 launches
i
which e v e r o c c u r s f i r s t , a t which t i m e they a r e
to be r e c e r t i f i e d by the m a n u f a c t u r e r .

One Is bound by the Melntenance Manuals for the nose hooks 'E 72'
and 'E 75' published in May 1875 and the Maintenance anual lor the
belly hooks 'Europe Q 72' and 'Europa Q 73' published in?A ay 1975.'

b ) Oxygen Equipment
Overhaul t i m e s for specific Oxygen equipment i s
given in t h e i r t e s t c e r t i f i c a t e s .
Oxygen bottles m u s t a l s o be checked by the tech-
n i c a l s e r v i c e e v e r y 5 y e a r s o r according to the
local l a n e s on u s e of p r e s s u r i z e d g a s e s .