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DG Flugzeugbau LS4 User Manual

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Maintenance Manual LS4
Issued: May 2011
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0-1
Recommendations to order spare parts
Please try to determine the exact designations of the spare parts for your order
using the maintenance manual. This is to guarantee a fast and correct delivery of
the parts.
The designations are to find in the sections system description, instructions for
assembly and servicing work and especially in the diagrams of the maintenance
manual.
Yours sincerely
DG FLUGZEUGBAU GMBH
Dipl.- Ing. W. Dirks

Table of Contents

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DG Flugzeugbau LS4 Specifications

General IconGeneral
BrandDG Flugzeugbau
ModelLS4
CategoryPlaner
LanguageEnglish

Summary

Recommendations to order spare parts

0 General

0.1 Manual amendments

Lists amendments to the manual with dates and descriptions.

0.2 List of effective pages

0.4 Airworthiness Limitations

0.4.1 Repairs

Instructions for airframe repairs and approved repair methods.

0.4.2 Life time of the airframe

Specifies the maximum operating time and inspection intervals.

0.4.3 Life time of equipment and components

Details life limitations for safety harness and other components.

0.4.4 Service time, maintenance documents of equipment and components

Refers to manufacturer instructions for service times of equipment.

1 Description of systems

1.1 Wings

Describes the wing construction and wingtips including variants.

1.2 Aileron control

Describes aileron control systems for different variants.

1.3 Elevator Controls and Trim-System

Describes elevator and trim system activation and controls.

1.4 Rudder control system

Describes the rudder control system operation.

1.5 Wheel brake

Describes the wheel brake operation.

1.6 Air brake controls

Describes air brake controls for different variants.

1.7 Water ballast system and sketches for wing control systems

Details water ballast systems and control system sketches.

1.8 Cockpit

Describes cockpit structure and controls for different variants.

1.9 Canopy

Describes canopy types and emergency release mechanisms.

1.10 Instrument panel

Describes instrument panel specifications for different variants.

1.11 Baggage compartment

Specifies use and weight limits for baggage compartment.

1.12 Oxygen system

Describes oxygen system specifications.

1.13 Landing gear

Describes landing gear operation and features.

1.14 Wheel Brake

Describes the wheel brake operation.

1.15 Hint for working at the control systems

Provides caution on corrosion and thread reach for control systems.

1.16 Pressure ports

Shows diagrams of pressure ports for different variants.

1.17 Drain orifices

Shows location of drain orifices.

1.18 Colour coding of instrument lines

Specifies colour code for instrument lines.

2 Mass and balance

2.1 Weighing procedure

Step-by-step guide for weighing the sailplane.

2.2 Calculation of loading limits, example

Details how to determine minimum cockpit load and examples.

2.3 Empty mass C.G. range

Provides tables for empty mass C.G. range.

2.4 Max. mass of non-lifting parts

Discusses maximum mass of non-lifting parts.

3 Inspections

3.1 Regular inspections

Outlines daily and annual inspection procedures.

3.2 Extraordinary inspections after heavy landings

Lists components for extraordinary inspections after rough landings.

3.3 Inspection procedure for increase of service time

Details inspection procedures for extending service life.

3.4 Lubrication schedule

Provides lubrication frequency and lubricant types for various parts.

4 Working instructions

4.1 Removal and installation of control surfaces

Provides instructions for removing and installing control surfaces.

4.2 Installation of control surface gap sealings and turbulators

Details installation of gap seals and turbulators.

4.3 Removal and installation of seat shell

Details removal and installation of seat shells for different variants.

4.4 Adjustment of water ballast valves

Describes adjustments for water ballast valves.

4.5 Removal and installation of the wing water ballast bags:

Describes removal and installation of wing water ballast bags.

4.6 Removal and installation of the tail fin water ballast tank (Option)

Describes removal and installation of the tail fin water ballast tank.

4.7 Removal and installation of the C.G. Hook

Describes removal and installation of the C.G. Hook.

4.8 Removal and installation of the nose hook (Option)

Describes removal and installation of the nose hook.

4.9 Canopy emergency release

Describes function check and operation of canopy emergency release.

5 Control surfaces

5.1 Control surface deflection limits

Specifies deflection limits for rudder, aileron, and elevator.

5.2 Control surface weight and mass balance

Provides weight and mass balance data for control surfaces.

5.3 Control surfaces free play

Specifies acceptable free play for control surfaces.

5.4 Control surfaces friction

Specifies acceptable friction for control surfaces.

6 Special tools:

7 Placards and markings

7.1 Placards and markings LS4

Lists placards for LS4, including minimum cockpit load.

7.2 Placards and markings LS4-a

Lists placards for LS4-a, including max takeoff mass.

7.3 Placards and markings LS4-b

Lists placards for LS4-b, including max takeoff mass.

8 Permanent installation of fixed ballast and equipment

8.1 Fixed ballast under instrument panel

Describes installation of ballast under the instrument panel.

8.2 Fixed Ballast at rear fuselage end

Describes installation of rear trim weight holder and ballast.

8.3 Permanent installation of equipment in baggage compartment

Details installation of equipment in the baggage compartment.

9 Instruments- and Equipment List (Master Equipment List)

9.1 Airspeed Indicator

Lists airspeed indicator models and TCDS numbers.

9.2 Altimeter

Lists altimeter models and TCDS numbers.

9.3 Seat Belt Harness (with multiple point buckles)

Lists seat belt harness manufacturers and TCDS numbers.

9.4 Compass

Lists compass manufacturers and TCDS numbers.

9.5 UHF – Transmitter and Receiver

Lists UHF transmitter/receiver models and TCDS numbers.

9.6 Variometer

Lists variometer models and TCDS numbers.

9.7 Turn and Bank Indicator

Lists turn and bank indicator manufacturers and TCDS numbers.

9.8 Thermometer

Lists thermometer manufacturer and type.

9.9 Electrical Supply

Details battery requirements and fuse positions.

9.10 Equipment, not being part of minimum equipment:

Lists optional equipment like transponders and gliders computers.

10 Materials for repair

Resinsystems for repairs

Lists resin and hardener systems for repairs.

Fibre Glass Fabric:

Lists fibre glass fabric types, mass, and usage.

Fibre Glass Rovings:

Lists fibre glass roving types.

Carbon Fibre Fabric (only LS4-b):

Lists carbon fibre fabric types and usage.

Polyester Fabric:

Lists polyester fabric types and usage.

Foam:

Lists types of foam used in construction.

Glue for Plexiglas

Lists glue and hardener for canopy attachment.

To repair cracks in the canopy:

Mentions hardening agent for canopy crack repair.

Filler

Describes fillers like cotton flocks and microballoons.

Paint

Lists paint types and mixing ratios.

Warning Colour:

Specifies warning colours for Nitro Cellulose Kombilack.

Sources for material

States where materials can be obtained.

11 Repairs

11.1 Preface

Introduces basic repair instructions for minor GFRP damage.

11.2 Repairs of composite structures, General

Provides general guidelines for composite structure repairs.

11.3 Tools and facilities required

Lists tools and facilities needed for FRP repairs.

11.4 Instructions for FRP repairs

Provides instructions and methods for FRP repairs.

11.5 Types of materials and overlap dimensions

Lists material types and overlap dimensions for repairs.

11.6 Control cables and connections

Details rudder cables, tow hook cables, and water ballast cables.

11.7 Longitudinal motion pushrod bearings

Cautions against pulling pushrods and greasing bearings.

12 Recommendations for maintenance and care of gelcoat surfaces

12.1 General

Recommends polish for gelcoat protection against UV light.

12.2 "Schwabbel" procedure:

Describes the polishing procedure using wax and cloth discs.

13 Transport of sailplane

13.1 Support areas for road-transport

Specifies support areas for fuselage, wings, and horizontal tail.

13.2 Support areas when lifting the entire plane

Lists support areas for lifting the entire aircraft.

13.3 Ground Towing

Provides guidance for ground towing.

14 Appendix

14.1 Annual inspection checklist

Checklist for annual inspections, covering various aircraft parts.

14.2 Instruction for maintenance of L’Hotellier ball and swivel joints

Provides maintenance instructions for L'Hotellier joints.

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