DG Flugzeugbau DG-1000T User manual

0.0
DG Flugzeugbau GmbH
Otto-Lilienthal-Weg 2 / Am Flugplatz  D-76646 Bruchsal  Germany
Postbox 1480, D-76604 Bruchsal  Deutschland
Tel. [phone]  Telefax 07251/3020-200  eMail: [email protected]
Spare part and material sales: Tel. [phone]  [email protected]
http://www.dg-flugzeugbau.de
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
MAINTENANCE MANUAL
FOR THE
MOTORGLIDER
DG-1000T
Type: DG-1000
Variant DG-1000T
Data Sheet No.: EASA.A.072
Factory Serial No.: __________________________
Registration No.: __________________________
Date of Issue: June 2005

Maintenance Manual DG-1000T
Issued: October 2010 TN 1000/19 0.1
0 General
0.1 Manual amendments
No. Page Description Date
1 0.3, 0.6, 0.10, 1.22,
1.23, diagram 15a
TN1000/09 October
2006
2 0.5, 0.6, 8.2,
diagram 15a
ÄM1000-1-07 December
2006
3 0.0, 0.3-0.6, 0.12, 1.1,
3.3, 4.2, 4.16, 4.17,
4.21, 4.28, 8.1, 8.4
diagrams 5, 6, 8 - 10,
12, 15, 15a,
5EP50, 5V18, 10FW2,
encl. 2 page 1
TN1000/10
Manual revision
January
2007
4 0.1, 0.6, diagram 14 TN1000/11
Manual revision
October
2007
5 0.3, 0.4, 0.6, 0.10, 1.9,
1.10, 4.7-4.9,
diagrams 17, 18
landing gear positive locking
device TN1000/13
February
2008
6 0.3, 0.4, 0.6, 0.10,
1.19, 2.1, diagram 19,
enclosure 3
TN1000/15
Throttle handle in rear Cockpit
Option
March 2008
7 0.3, 0.6, 0.10, 1.14
diagram 6a
ÄM1000-02
Fin ballast tank valve and handle
March 2008
8 0.4, 0.5, 0.6, 1.31, 2.6,
4.18, 6.2, 8.3, diagram
16, enclosure 2 pages 2
and 3
Manual revision TM1000/16 May 2008
9 0.3, 0.4, 0.6, 0.10, 4.8,
4.9, diagram 7a
ÄM1000-04
Production version of the positive
locking device
Oct. 2008
10 0.3, 0.6, 0.10, diagrams
20-22, drawing 10E4,
enclosure 4
Electrically operated main landing
gear
TN1000/14
November
2008
11 0.6 and 0.10, diagram
21, Encl. 4 pages 2, 2a
and 7.
drawing 10E4 issue E
Electrically operated landing gear,
device to provide higher current for
resetting the emergency extension
gas strut TN1000/19
October
2010

Maintenance Manual DG-1000T
Issue: July 2017 TN1000/32 0.2
No. Page Description Date
12 0.2÷ 0.9, 0.9a, 0.10 ÷ 0.12,
1.2, 1.5, 1.11, 1.14, 1.15,
1.27 ÷ 1.29, 1.33, 2.1,
2.4 ÷ 2.6, 3.3, 4.8, 5.1, 6.1,
6.2, 6.4, 8.3, 9.2, diagr. 1,
9, 11, encl. 4 pages 1, 2, 2a,
3, Z193, SI 67-07, remove
5EP50
Manual revision TN1000/18 February
2011
13 0.6, diagrams 8 and 9 Wheel brake TN1000/21 July 2011
14 0.2 ÷ 0.7, 0.10 ÷ 0.12, 1.3,
1.5, 1.11, 1.16, 1.29, 1.30,
2.1, 2.6, 3.1, 4.6, 4.10,
4.12, 4.13, 4.19, 4.20, 6.1,
7.1, 8.2, 8.3,
diagrams: 2, 3, 9,
Enclosure 4 pages: 4, 7
Manual revision TN 1000/24,
New type 12V sockets and
plugs,
Changes due to TN 4603-14 of
the Solo company (Exchange
of the axle of the upper drive
belt pulley on pages 4.19 and
4.20)
October
2014
15 0.2, 0.3 - 0.6, 0.9a, 0.11,
1.18, 3.5, 3.8, 4.20, 4.20a,
4.26, 4.28, 8.1 – 8.3
diagram 13, diagram 15,
diag0ram 15a
Propeller adapter ring with
elastomeric damper
TN 1000/26
Alternative mechanical fuel
pump TN 1000/28
August
2015
16 0.2 -0.6, 0.11, 0.12, 2.1,
2.2, 3.7, 6.3, 8.2, 8.3,
diagram 2
Manual revision
TN1000/32
July 2017

Maintenance Manual DG-1000T
Issued: July 2017 TN1000/32 0.3
0.2 List of effective pages
Section page issued replaced/ replaced/ replaced/
0 0.0 June 2005 January 2007
0.1 see manual amendments
0.2 "
0.3 "
0.4 "
0.5 "
0.6 "
0.7 June 2005 January 2007 Febr. 2011 Oct. 2014
0.8 " Febr. 2011
0.9 " Febr. 2011
0.9a Febr. 2011 August 2015
0.10 " Febr. 2008
Nov. 2008
March 2008
Febr. 2011
Oct. 2008
Oct. 2014
0.11 " Febr. 2011
July 2017
Oct. 2014 August 2015
0.12 " January 2007
July 2017
Febr. 2011 Oct. 2014
1 1.1 June 2005 January 2007
1.2 " Febr. 2011
1.3 " Oct. 2014
1.4 "
1.5 " Febr. 2011 Oct. 2014
1.6 "
1.7 "
1.8 "
1.9 " Febr. 2008
1.10 " Febr. 2008
1.11 " Febr. 2011 Oct. 2014
1.12 "
1.13 "
1.14 " March 2008 Febr. 2011
1.15 " Febr. 2011
1.16 " Oct. 2014
1.17 "
1.18 " August 2015
1.19 " March 2008
1.20 "
1.21 "
1.22 " October 2006
1.23 " October 2006
1.24 "

Maintenance Manual DG-1000T
Issued: July 2017 TN1000/32
0.4
0.2 List of effective pages (continued)
Section page issued replaced/ replaced/ replaced/
1.25 "
1.26 "
1.27 " Febr. 2011
1.28 " Febr. 2011
1.29 " Febr. 2011 Oct. 2014
1.30 " Oct. 2014
1.31 " May 2008
1.32 "
1.33 " Febr. 2011
2 2.1 June 2005 March 2008
July 2017
Febr. 2011 Oct. 2014
2.2 " July 2017
2.3 "
2.4 " Febr. 2011
2.5 " Febr. 2011
2.6 " May 2008 Febr. 2011 Oct. 2014
3 3.1 June 2005 Oct. 2014
3.2 "
3.3 " Febr. 2011
3.4 "
3.5 " August 2015
3.6 "
3.7 " July 2017
3.8 " August 2015
3.9 "
4 4.1 June 2005
4.2 " January 2007
4.3 "
4.4 "
4.5 "
4.6 " Oct. 2014
4.7 " Febr. 2008
4.8 " Febr. 2008 Oct. 2008 Febr. 2011
4.9 " Febr. 2008 Oct. 2008
4.10 June 2005 Oct. 2014
4.11 "
4.12 " Oct. 2014

Maintenance Manual DG-1000T
Issued: July 2017 TN1000/32
0.5
0.2 List of effective pages (continued)
Section page issued replaced/ replaced/ replaced/
4.13 " Oct. 2014
4.14 "
4.15 "
4.16 " January 2007
4.17 " January 2007
4.18 " May 2008
4.19 " Oct. 2014
4.20 " Oct. 2014 August 2015
4.20a August 2015
2.21 " January 2007
4.22 "
4.23 "
4.24 "
4.25 "
4.26 " August 2015
4.27 "
4.28 " January 2007 August 2015
4.29 "
4.30 "
4.31 "
5 5.1 June 2005 Febr. 2011
5.2 "
6 6.1 June 2005 Febr. 2011 Oct. 2014
6.2 " May 2008 Febr. 2011
6.3 " July 2017
6.4 " Febr. 2011
7 7.1 June 2005 Oct. 2014
8 8.1 June 2005 January 2007 August 2015
8.2 " Dec. 2006 January 2007 Oct. 2014
August 2015 July 2017
8.3 " May 2008 Febr. 2011 Oct. 2014
August 2015 July 2017
8.4 " January 2007
9 9.1 June 2005
9.2 " Febr. 2011

Maintenance Manual DG-1000T
Issued: July 2017 TN1000/32 0.6
0.2 List of effective pages (continued)
diagram issued replaced/ replaced/ replaced/
1 May 2004 Oct. 2010
2 Nov. 2001 Oct. 2014 July 2017
3 June 2005 Oct. 2014
4 Nov. 2001
5 Nov. 2001 January 2007
6 Nov. 2001 January 2007 March 2008 Not valid for 10-
101, and from 10-128 on
6a March 2008
7 Nov. 2004
7a Oct. 2008
8 Nov. 2001 January 2007 July 2011
9 June 2005 January 2007
Oct. 2014
Febr. 2011 July 2011
10 May. 2005 January 2007
11 June 2005 Febr. 2011
12 Sept. 2003 January 2007
13 June 2005 August 2015
14 June 2005 October 2007
15 June 2005 January 2007 August 2015
15a Oct. 2006 Dec. 2006 January 2007 August 2015
16 June 2005 May 2008
17 Febr. 2008
18 Febr. 2008
19 March 2008
20 Nov. 2008
21 Nov. 2008 Oct. 2010
22 Nov. 2008
5EP34 25.01.90
5V18 14.10.94
10FW2 05.10.99
10E4 issue A 28.10.08
10E4 issue E 8.10.10
10E102 14.09.05 5.12.05 26.01.06
10E103 24.06.05
Encl. 1 June 2005
Encl. 2 June 2005 Page 1
January 2007
Pages 2, 3
May 2008
Encl. 3 March 2008
Encl. 4 Nov. 2008 Page 2, 2a , 7
Oct. 2010
1, 2, 2a, 3
Febr. 2011
4, 7
Oct. 2014
SI 67-07 5.11.2007
Z193 4.11.2009

Maintenance Manual DG-1000T
Issued: October 2014 TN1000/24 0.7
0.3 Content
Section content page
0 General 0.1
0.1 Manual amendments .......................................................................... 0.1
0.2 List of effective pages ........................................................................ 0.3
0.3 Content ............................................................................................... 0.7
0.4 Airworthiness limitations ................................................................. 0.11
0.4.1 Repairs ......................................................................................... 0.11
0.4.2 Life time of the airframe .............................................................. 0.11
0.4.3 Life time of components .............................................................. 0.11
0.4.4 Service time, maintenance documents ......................................... 0.12
1 System description and adjustment data 1.1
1.1 Wing and tailplane setting data .......................................................... 1.1
1.2 Elevator control and trim system ....................................................... 1.2
1.2.1 Control system ............................................................................... 1.2
1.2.2 Elevator deflections and tolerances ............................................... 1.2
1.2.3 Elevator stops ................................................................................. 1.2
1.2.4 Elevator control circuit free play ................................................... 1.3
1.2.5 Trim ................................................................................................ 1.3
1.2.6 Pilot force reducing rubber-cord .................................................... 1.4
1.3 Rudder control .................................................................................... 1.5
1.3.1 Rudder control circuit .................................................................... 1.5
1.3.2 Rudder deflections and tolerances ................................................. 1.5
1.3.3 Rudder stops ................................................................................... 1.5
1.3.4 Axial space and free play ............................................................... 1.5
1.3.5 Seal the rudder ............................................................................... 1.5
1.3.6 Retaining spring for the pedal adjustment handle………………..1.5
1.4 Aileron control ................................................................................... 1.6
1.4.1 Control circuit ................................................................................ 1.6
1.4.2 Deflections and tolerances ............................................................. 1.6
1.4.3 Stops ............................................................................................... 1.6
1.4.4 Free play ......................................................................................... 1.6
1.4.5 Complete readjustment .................................................................. 1.7
1.5 Airbrake control, wheelbrake ............................................................. 1.8
1.5.1 Control circuit ................................................................................ 1.8
1.5.2 Adjustment ..................................................................................... 1.8
1.5.3 Airbrake stops ................................................................................ 1.8
1.5.4 Free play ......................................................................................... 1.8
1.6 Undercarriage ..................................................................................... 1.9
1.6.1 Main wheel (Version without nose wheel) .................................... 1.9
1.6.2 Main wheel (Version with nose wheel) ....................................... 1.10
1.6.3 Main wheel (non retractable Version) ......................................... 1.11
1.6.4 Hydraulic brake system ............................................................... 1.11
1.6.5 Wheels, tyres, tyre pressures ........................................................ 1.11

Maintenance Manual DG-1000T
Issued: February 2011 TN1000/18 0.8
Section content page
1.7 Tow hooks ........................................................................................ 1.12
1.7.1 Tow release circuit ....................................................................... 1.12
1.7.2 Adjustment ................................................................................... 1.12
1.7.3 Damages ....................................................................................... 1.12
1.7.4 Removing the tow hooks ............................................................. 1.12
1.7.5 Rubber cords ................................................................................ 1.12
1.8 Water ballast system ........................................................................ 1.13
1.8.1 Wingtanks .................................................................................... 1.13
1.8.2 Fin tank ........................................................................................ 1.14
1.9 Ballast box in the fin ........................................................................ 1.15
1.9.1 Inspection of the control light in the front instrument panel ....... 1.15
1.9.2 Protection of the control light ...................................................... 1.15
1.9.3 Inspection of the locking device of the ballast box cover plate... 1.15
1.9.4 Inspection of the foam rubber rings ............................................. 1.15
1.10 Massbalance and weights of control surfaces .................................. 1.16
1.11 Fore and aft play of the wings.......................................................... 1.17
1.11.1 At fuselage ................................................................................... 1.17
1.11.2 At the wing parting ...................................................................... 1.17
1.12 Power Plant ...................................................................................... 1.18
1.12.1 Arrangement: ............................................................................... 1.18
1.12.2 Engine: ......................................................................................... 1.18
1.12.3 Exhaust Muffler: .......................................................................... 1.18
1.12.4 Propeller: ...................................................................................... 1.18
1.12.5 Drive belt reduction gear: ............................................................ 1.18
1.12.6 Starter: .......................................................................................... 1.19
1.12.7 Ignition system: ............................................................................ 1.19
1.12.8 Throttle cable connections ........................................................... 1.19
1.12.9 Propeller stopper .......................................................................... 1.19
1.12.10 Tightening torques and locking: .................................................. 1.20
1.13 Retraction - Extension Mechanism .................................................. 1.20
1.13.1 Layout .......................................................................................... 1.20
1.13.2 Extension force of the gas-strut ................................................... 1.20
1.13.3 Adjusting the powerplant retaining cable .................................... 1.20
1.13.4 Position switches .......................................................................... 1.21
1.13.5 Adjustment of the powerplant positions ...................................... 1.21

Maintenance Manual DG-1000T
Issued: February 2011 TN1000/18 0.9
Section content page
1.14 Fuel system ...................................................................................... 1.22
1.14.1 Layout .......................................................................................... 1.22
1.14.2 Tank ............................................................................................. 1.22
1.14.3 Refuelling ..................................................................................... 1.22
1.14.4 Excess fuel line ............................................................................ 1.22
1.14.5 Fuel pumps ................................................................................... 1.23
1.14.6 Fuel cock ...................................................................................... 1.23
1.14.7 Fuel filter ...................................................................................... 1.23
1.14.8 Fuel quantity indication ............................................................... 1.23
1.14.9 Carburettor ................................................................................... 1.24
1.14.10 Fuel injection (primer) ................................................................. 1.26
1.15 Electrical system .............................................................................. 1.27
1.15.1 Layout .......................................................................................... 1.27
1.15.2 Batteries ....................................................................................... 1.27
1.15.3 Control unit .................................................................................. 1.28
1.15.4 Master Switch: ............................................................................. 1.28
1.15.5 Engine elapsed - time indicator: .................................................. 1.28
1.15.6 Electric fuel pump: ....................................................................... 1.28
1.15.7 12 V Socket: ................................................................................. 1.29
1.15.8 Power plant extension-retraction mechanism: ............................. 1.29
1.15.9 Manual extension-retraction switch ............................................. 1.29
1.15.10 Starter Press Button...................................................................... 1.30
1.15.11 Wiring .......................................................................................... 1.30
1.15.12 Circuit breakers and fuses ............................................................ 1.31
1.15.13 Position switches for the powerplant ........................................... 1.31
1.15.14 Proximity switch .......................................................................... 1.32
1.15.15 Refuelling pump systems ............................................................. 1.32
1.15.16 Connector plugs between fuselage and engine ............................ 1.33
1.15.17 DEI NT= (Digital Engine Indicator) ............................................ 1.33
2 Inspections 2.1
2.1 Daily inspection ................................................................................. 2.1
2.2 Regular inspections ............................................................................ 2.1
2.3 Inspections after a heavy landing ....................................................... 2.3
2.4 Inspection procedure for increase of service time ............................. 2.6
3 Maintenance 3.1
3.1 General maintenance .......................................................................... 3.1
3.2 Maintenance of the airframe .............................................................. 3.2
3.3 Greasing and oiling ............................................................................ 3.3
3.4 Damage of the airframe ..................................................................... 3.4
3.5 Hydraulic wheel brake ....................................................................... 3.4
3.6 Servicing the Engine .......................................................................... 3.5

Maintenance Manual DG-1000T
Issued: August 2015 TN1000/26 a
0.9
4 Detailed instructions for assembly and servicing work 4.1
4.1 Water ballast system .......................................................................... 4.1
4.2 Replacement of control circuit cables ................................................ 4.2
4.3 Adjustment and servicing of the control circuit ................................ 4.2
4.4 Inspection and adjustment of the airbrakes........................................ 4.3
4.4.1 Retracted position .......................................................................... 4.3
4.4.2 Overcentre locking moment and locking travel ............................ 4.4
4.5 Removal and installation of the undercarriage (main wheel) ............ 4.6
4.5.1 Undercarriage (main wheel), Version without nose wheel ........... 4.6
4.5.2 Undercarriage (main wheel), Version with nose wheel .............. 4.10
4.6 Filling and bleeding the hydraulic disc brake .................................. 4.12
4.7 Control surface seals and turbulators ............................................... 4.14
4.7.1 Ailerons ........................................................................................ 4.14
4.7.2 Wing lower surface ...................................................................... 4.16
4.7.3 Horizontal tailplane ...................................................................... 4.16
4.7.4 Vertical tailplane .......................................................................... 4.17
4.8 Working instructions for heat-shrink tubing .................................... 4.18
4.9 Securing with Loctite ....................................................................... 4.18
4.10 Working at the powerplant ............................................................... 4.19
4.10.1 Mounting and tensioning of the drive belts ................................. 4.19
4.10.2 Mounting the propeller ................................................................ 4.20
4.10.3 Removal and installation of the fuel tank .................................. 4.20a
4.10.4 Replacement of the engine retaining cable .................................. 4.21
4.10.5 Removal and installation of gas-strut and spindle drive .............. 4.23
4.10.6 Installation and removal of the powerplant ................................. 4.24
4.10.7 Removal and installation of the engine doors.............................. 4.29
4.10.8 Securing the fuel hoses with lockwire ......................................... 4.29
4.11 DEI-NT settings ............................................................................... 4.30
4.11.1 Calibration of the fuel display in the DEI-NT ............................. 4.30
4.11.2 Further DEI-NT settings .............................................................. 4.30
5 Weight and balance 5.1
6 Instrumentation and accessories list 6.1
7 List of special tools etc. 7.1
8 Partlist 8.1
8.1 Parts for the powerplant ..................................................................... 8.1
8.2 Parts for fuel system ........................................................................... 8.2
8.3 Parts for the electrical system ............................................................ 8.3
8.4 Control surface seals and turbulators ................................................. 8.4
9 Enclosures 9.1
9.1 Equipment list .................................................................................... 9.1
9.2 Checklist for checks and maintenance work...................................... 9.2

Maintenance Manual DG-1000T
Issued: October 2014 TN1000/24 0.10
diagrams
1 Elevator control, trim
2 Rudder control
3 Controls in the fuselage (Aileron and spoiler controls)
4 Controls in the wings (Aileron and spoiler controls)
5 Tow releases
6 Water ballast system
6a Waterballast system 10-101, from 10-128 on
7 Landing gear, hydraulic wheel brake (Version without nose wheel)
up to ser. No. 10-132
7a Landing gear, hydraulic wheel brake (Version without nose wheel)
from ser. No. 10-133 on
8 Landing gear, hydraulic wheel brake (Version with nose wheel)
9 Landing gear, non retractable
10 Systems for static and total pressure
11 Placards
12 Landing gear control (Version without nose wheel)
13 Powerplant
14 Extension/retraction mechanism
15 Fuel system
15a Fuel system with automatic fuel cock
16 Powerplant retaining cables
17 Landing gear positive locking device TN1000/13
no more valid from ser. No. 10-133 on
18 Actuation unit LG locking device, differences to diagr. 12
for TN1000/13 and from ser. no. 10-133 on
19 Throttle handle in front and rear Cockpit TN1000/15
20 Electrically operated main landing gear (in landing gear box)
21 Electrically operated main landing gear (outside landing gear box)
22 Placards electrically operated main landing gear
5EP34 Installation plan Dräger oxygen system
5V18 Tool for airbrake adjustment
10FW2 Spring leg (landing gear)
10E4 Wiring plan electrically operated main landing gear TN1000/14
10E4
Issue E
Wiring plan electrically operated main landing gear TN1000/19
10E102 Wiring plan DINA1 (in aircraft log)
10E103 Wiring scheme
Encl. 1 Download instructions for flightlog and service data from the DEI-NT
Encl. 2 Instructions for transponder installation
Encl. 3 Throttle handle in front and rear Cockpit TN1000/15
Encl. 4 Electrically operated main landing gear
SI 67-07 Service Info ballast box in the fin foam rubber rings
Z193 406 MHZ ELT antenna BD3 installation 2-seaters

Maintenance Manual DG-1000T
Issued: July 2017 TN1000/32 0.11
0.4 Airworthiness limitations
0.4.1 Repairs
Repair or replace damaged parts prior to next flight. Follow the instructions of
the DG-1000 repair manual for repairs of the airframe. Repairs outside the scope
of DG-1000 repair manual and major repairs must be accomplished at a certified
repair station or by a certified mechanic rated for composite aircraft structure
work in accordance with DG repair methods.
Use only genuine spare parts.
For all aircraft under EASA regulations the following applies: According to part
21, subpart M to accomplish major repairs an approved repair instruction is
required, see also TN DG-G-01 “Approved repair methods according to EU
Commission Regulation 1702/2003 part 21, subpart M”
0.4.2 Life time of the airframe
The maximum allowable operating time for German composite sailplanes and
motor gliders was proofed for 12000 flight hours. The initial life time for the
DG-1000T is 3000 flight hours and may be increased by inspections according
to section 2.4 of this manual to 6000 h, 9000 h, 10000 h, 11000 h and 12000 h.
0.4.3 Life time of components
Use only genuine spare parts. For part. No.’s of all parts please refer to section
8.
a) The gasket for the drainer valve has to be exchanged after 6 years, part no.
60504402.
b) The spark plugs have to be exchanged after 25 engine hours, part
no.40050360.
c) The fabric straps of the safety harness have to be exchanged according to
the instructions of the respective manufacturer. If no limitations are given,
exchange after 12 years, approved types see section 6.
d) The rubber cord in the elevator control system see section 1.2.6 has to be
replaced at least every 6 years, part no. 30091131.
e) The adapter ring with elastic damping element 10M067 for the propeller
(introduced with TN1000/26) has to be exchanged after 50 engine hours or 5
years, whichever comes first.
f) The eccentric axle of the reduction gear (propeller axle) Solo part no.
2031211-V2 has to be replaced after 50 engine hours
Note: The brake fluid of the wheel brake has to be exchanged after 4 years
(types see section 1.6.2).
Note:All other components like propeller, tow hook, wheels, gas struts, control
system parts, bolts, pins etc. have no life time limitation, but should be replaced
when worn, damaged or disqualified by excessive corrosion.

Maintenance Manual DG-1000T
Issued: July 2017 TN1000/32 0.12
0.4.4 Service time, maintenance documents
Follow the instructions of the respective manufacturer:
a) Operating Manual for Safety Tow Releases
Series: Europa G 88 Safety Tow Release
latest approved version
Operating Manual for Tow Releases
Series: E 85 Nose Tow Release
latest approved version
b) Safety harness: instructions of the manufacturer latest approved version.
Approved types see section 6.
c) Minimum instrumentation: instructions of the manufacturer, approved
instruments see sections 6.
d) Engine: Manual for the engine SOLO Type 2350 C, latest approved version.
e) Operating- and Service Instructions for propeller DG-P001 latest approved
version.
Note only for USA: The Airworthiness Limitations section is FAA approved
and specifies maintenance required under Secs. 43.16 and 91.403 of the Federal
Aviation Regulation unless an alternative program has been FAA approved.
LBA approved

Maintenance Manual DG-1000T
Issued: January 2007 TN1000/10 1.1
1 System description and adjustment data
1.1 Wing and tailplane setting data
Wing:
Sweep Back (Leading edge): 0° between y= 3490 mm (137 in.)
and y= 6979 mm (275 in.)
Dihedral (Leading edge line): inboard wing panel up to parting: 2,5°
to measure: 152 mm (6 in.) between
y= 3490 mm (137 in.)
and y= 6979 mm (275 in.)
outboard wing panels: 14.5°
Angles of Incidence: -0,3° at the wing root, +1° from
y=1200 mm (47 in.) up to tip
Horizontal tailplane: -2,5°
fuselage center line
(corresponding to boom slope 1000:33)
Wing oscillation frequency: ca. 125/min 20 m wing span
ca. 143/min 18 m wing span
Aircraft should rest on main wheel and tailwheel during frequency
measurements.

Maintenance Manual DG-1000T
Issued: February 2011 TN1000/18 1.2
1.2 Elevator control and trim system
1.2.1 Control system
see diagram 1
1.2.2 Elevator deflections and tolerances
up: 27° u= 77 up to 79 mm (3.03 up to 3.11)
down: 21° d= 61 up to 63 mm (2.40 up to 2.48)
measured at 168 mm (6.61 in.) from hinge axis which is directly at the edge of
the cut out for the rudder
Measurement:
 Hold a measuring stick with one end on the floor, the stick must be vertical
when touching the elevator trailing edge.
 Set the elevator to zero by using a pattern. A drawing for the zero-pattern is
available from DG Flugzeugbau.
 Mark the 0-point on the stick.
 Then measure the up and down deflections according to the sketch.
1.2.3 Elevator stops
The elevator stops are located at the rear control column and can be adjusted
with a 10 mm open end wrench.
u
d

Maintenance Manual DG-1000T
Issued: October 2014 TN1000/24 1.3
1.2.4 Elevator control circuit free play
With the elevator held fixed in the zero position, the free play at the top of the
control column can be + 2 mm (+ 0.08 in.). Within the automatic elevator
connection there should be no free play noticeable in the zero position when the
elevator is moved at its trailing edge.
Any free play can be reduced by screwing in the adjustment screw on the
automatic connector funnel.
1.2.5 Trim
The trim mechanism should be adjusted so that with full forward (nose down)
trim the control column is pulled by the trim springs into it’s maximum forward
position with a force P of approx. 30 N (6.6 lbs.).
The force P is to be measured with a spring balance at the upper end of the
control stick. Read the force, when the stick just starts to move.
The tensioning of the trim mechanism springs is adjusted as shown in the sketch.
x = 340 mm (13.4 in.)
The springs are located in the rear cockpit on the left hand side.
The correct adjustment should be verified in flight and corrected if necessary.
Trimming should be possible up to 200 – 220 km/h (108 - 119 kts.).
Note: If the DG-1000T can be trimmed up to higher speeds it is likely that the
trim is not sufficient in circling flight.
elevator
locking nut
adjustment screw

Maintenance Manual DG-1000T
Issued: October 2014 TN1000/24 1.4
1.2.6 Pilot force reducing rubber-cord
The rubber cord produces an elevator stick force in push direction. If the trim
efficiency of your glider in push direction is reduced, you have to inspect the
rubber cord.
The rubber cord is located on the left hand side behind the main bulkhead below
the baggage compartment floor. The rubber cord runs from bellcrank 5St19 to a
fork beside the left hand front edge of the landing gear box.
The length of the rubber cord when loose should be 470 mm (18.5 in.).
If the cord is longer or worn it must be replaced.
The cord must be replaced at least every 6 years.

Maintenance Manual DG-1000T
Issued: October 2014 TN1000/24 1.5
1.3 Rudder control
1.3.1 Rudder control circuit
see diagram 2
1.3.2 Rudder deflections and tolerances
28° up to 29° which is 160 up to 165 mm (6.3 up to 6.5 in.) to both sides
measured at 330 mm (13 in.) behind the hinge axis (lower rear end of the
rudder).
1.3.3 Rudder stops
The rudder stops are located at the lower hinge of the rudder.
1.3.4 Axial space and free play
The maximum allowable space including free play at the upper hinge point is
1mm (0.04 inch).
1.3.5 Seal the rudder
The rudder is sealed on both sides. On the outside Mylar seals and inside the fin
with V seal tapes.
These seals are not to be removed.
If damaged replace the seals according to section 4.7.4.
1.3.6 Retaining spring for the pedal adjustment handle
A rubber cord with 2 mm (0.08 in.) diameter which pulls the pedal adjustment
cable tight is installed in the console below the instrument panel. If this rubber
cord is defective the handle of the pedal adjustment cable won’t be pulled to the
front so that it may hook into the trim release lever at the control stick with
pedals in a rear position.
1 mm

Maintenance Manual DG-1000T
Issued: December 2005 1.6
1.4 Aileron control
1.4.1 Control circuit
see diagrams 3 and 4.
1.4.2 Deflections and tolerances
Aileron deflections: up 25° 71±2 mm (2.8 ± 0.08 in.)
down 12° 34±2 mm (1.34 ± 0.08 in.)
measured at 164 mm (6.46 in.) from hinge axis (at the aileron root)
1.4.3 Stops
The aileron stops are located at the rear control column and can be adjusted with
two 10 mm open-end wrenches.
1.4.4 Free play
The max. free play at the trailing edge of the ailerons measured at 164mm (6.46
in.) from hinge axis should not exceed ± 1.5 mm (± 0.06 in.) with the control
stick in neutral position and fixed.
With both ailerons fixed, a maximum free play of ± 2 mm (± 0.08 in.) at the top
of the control stick is allowed.