DG Flugzeugbau DG-800A User Manual

DG Flugzeugbau GmbH
Otto-Lilienthal-Weg 2 / Am Flugplatz  D-76646 Bruchsal  Germany
Postbox 1480, D-76604 Bruchsal  Deutschland
Tel. 07251/3020-100  Telefax 07251/3020-200  eMail: dg@dg-flugzeugbau.de
Spare part and material sales: Tel. 07251/3020-270  lager@dg-flugzeugbau.de
http://www.dg-flugzeugbau.de
MAINTENANCE MANUAL
FOR THE
MOTORGLIDER
DG-808C
Type: DG-800A
Model: DG-808C
Data Sheet No.: EASA A.067 (LBA873)
Factory Serial No.: __________________________
Registration No.: __________________________
Date of issue: June 2005
Issued: July 2017

DG Flugzeugbau DG-800A Specifications

General

Type	Sailplane
Manufacturer	DG Flugzeugbau
Model	DG-800A
Stall Speed	65 km/h
Water Ballast	180 kg
Maximum Speed	270 km/h
Minimum Sink Rate	0.6 m/s

Summary

0 General

0.1 Manual Amendments

Details revisions made to the manual, including page numbers and descriptions of changes.

0.2 List of Effective Pages

Lists all pages included in the manual and their revision status.

0.3 List of Content

Provides a detailed breakdown of sections and their corresponding page numbers.

0.4 Airworthiness Limitations

Outlines critical maintenance intervals and life limits for airworthiness.

1 System Description and Adjustment Data

1.1 Wing and Tailplane Setting Data

Specifies geometric settings for wings and tailplane, including angles and dimensions.

1.2 Elevator Control and Trim System

Details the elevator control system, deflections, tolerances, and trim mechanism.

1.3 Rudder Control

Describes the rudder control system, deflections, tolerances, and sealing.

1.4 Aileron and Wing Flap Control

Explains the aileron and wing flap control systems, deflections, and adjustments.

1.5 Airbrake Control, Wheelbrake

Covers the airbrake and wheelbrake control circuits, adjustments, and stops.

1.6 Undercarriage

Details the main and tailwheel undercarriage systems, including adjustments and tyre pressure.

1.7 Tow Hooks

Provides information on tow release circuits, adjustment, damages, and removal.

1.8 Water Ballast System

Explains the water ballast system, including wing and fin tanks, and their adjustments.

1.9 Massbalance and Weights of Control Surfaces

Lists weight and moment limits for control surfaces after repairs or repainting.

1.10 Fore and Aft Play of the Wings

Describes how to check and adjust fore and aft play in wing joints and tolerances.

1.11 Power Plant

Covers engine type, coolant, propeller, drive belt, starter, and ignition system details.

1.12 Retraction - Extension Mechanism

Details the retraction and extension mechanism for the powerplant, including switches and adjustments.

1.13 Fuel System

Explains the fuel system components, tanks, refuelling, fuel pumps, cock, filter, and quantity indication.

1.14 Electrical System

Covers batteries, control unit, generator, master switch, and wiring.

1.15 Pitot and Static System

Outlines the layout and maintenance for the pitot and static system.

1.16 Ventilation and Drain Holes

Describes the layout and maintenance for ventilation and drain holes.

2 Inspections

2.1 Daily Inspection

Lists checks to be performed daily as per the flight manual.

2.2 Regular Inspections

Details annual and special inspections, including checks for various aircraft components.

2.3 Inspections after a Heavy Landing

Specifies checks required after a heavy landing to ensure structural integrity.

2.4 Inspection Procedure for Increase of Service Time

Outlines the procedure for extending the glider's service time based on fatigue tests.

2.5 Inspection Procedure for the Controls

Describes specific checks for flaperon and airbrake controls at the wing roots.

3 Maintenance

3.1 General Maintenance

Covers general care of exterior surfaces, plexiglas canopy, and metal parts.

3.3 Greasing and Oiling

Details greasing points and procedures for bearings, hinges, and mechanisms.

3.4 Damage of the Airframe

Provides guidance on identifying and reporting airframe damage, distinguishing minor from major.

3.5 Servicing the Engine

Outlines engine servicing tasks, including 25-hour inspections and component replacements.

4 Detailed Instructions for Assembly and Servicing Work

4.1 Water-Ballast System

Provides instructions for replacement of water ballast bags and system checks.

4.2 Replacement of Control Circuit Cables

Details approved cable construction and replacement procedures for control circuits.

4.3 Adjustment and Servicing of the Control Circuit

Explains adjustments for control circuits, including nut and bolt specifications.

4.4 Removal and Installation of the Undercarriage (Main Wheel)

Provides step-by-step instructions for removing and installing the main undercarriage.

4.5 Fixing Excessive Free Play of the Canopy

Describes methods for fixing excessive free play in the canopy hinge.

4.6 Removal and Installation of the Flaperons

Details procedures for removing and reinstalling flaperons, including sealing.

4.7 Control Surface Seals and Turbulators

Explains the installation and maintenance of seals and turbulators on control surfaces.

4.10 Securing with Loctite

Provides instructions and cautions on using Loctite for securing bolts and threads.

4.11 Replacement of Wing Fuel Tanks (Option)

Details the procedure for replacing optional wing fuel tanks.

4.12 Mounting and Tensioning of the Drive Belt

Describes how to mount and tension the drive belt, including measurements and tolerances.

4.13 Replacing the Bearings of the Upper Drive Belt Pulley

Provides instructions for removing and installing bearings for the upper drive belt pulley.

4.17 Installation and Removal of the Powerplant

Covers general notes and necessary tools for powerplant removal and installation.

4.19 Securing the Propeller Bolts

Details the procedure for securing propeller bolts using lockwire.

4.20 Checking the Ignition Unit

Outlines procedures for checking the ignition unit, including troubleshooting steps.

4.22 Calibration of the Fuel Display in the DEI-NT

Explains how to calibrate the fuel display after DEI-NT replacement or repair.

5 Weight and Balance

C.G. Empty

Details the procedure for calculating the empty center of gravity (C.G.).

C.G. in Flight

Explains how to calculate the center of gravity (C.G.) with pilot and payload.

6 Instrumentation and Accessories List

Air Speed Indicator

Lists types and certification numbers for airspeed indicators.

Altimeter

Lists types and certification numbers for altimeters.

Compass

Lists types of compasses and their certification numbers.

VHF Transceiver

Lists types of VHF transceivers and their certification numbers.

Variometer

Lists types and certification numbers for variometers.

Engine Instrumentation

Lists engine instruments like DEI-NT, OAT, RPM, CHT, EGT.

7 List of Special Tools

A Special 13 mm Wrench

Lists a specific wrench for tailplane mounting, supplied with the glider.

C Open End Spanners

Lists various sizes of open-end spanners required for maintenance.

D Allen Key Wrench

Lists required Allen key wrench sizes for maintenance tasks.

J Torque Wrench

Specifies torque wrenches and their ranges for assembly and maintenance.

K Torque Wrench

Specifies torque wrenches and their ranges for sparkplugs and other components.

8 Partlist

8.1 Parts for the Powerplant

Lists parts required for the 25-hour engine inspection.

8.2 Parts for the Electrical System

Lists parts related to the aircraft's electrical system, including batteries and switches.

8.3 Control Surface Sealings and Turbulators

Lists materials for control surface seals and turbulators, including part numbers.

9 Enclosures

9.1 Equipment List

A table to log installed equipment with details like type, mass, and dates.

9.2 Checklist for Checks and Maintenance Work

A checklist template for recording engine maintenance tasks and intervals.