DG Flugzeugbau DG-500M User manual

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 0.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0General
0.1 Amendments
No. Page Description Date
0.1 all New standardized format of
the initial Maintenance
Manual of Variant DG-500M
December 2009
0.2 0.10, 1.15, 1.22,
1.27, 2.1, 3.9, 4.2,
4.15, 5.1, 6.2, 8.1-
8.3
Miscellaneous changes to the
contents of the latest
amendment of the initial
maintenance manual
December 2009
1 0.3, 0.6, 0.9, add
diagram 7a
Wheel brake
TN500/03
July 2011
2 0.3, 0.4, 0.6, 0.9,
1.10, 2.1, 2.3, 2.6,
2.8,, 2.9, 4.5, 4.6,
file working
instruction No. 1 for
TN348/20 issue 3 at
the end of the MM
Headrest securing ropes in the
rear cockpit, manual
amendments
TN500/05
September 2011

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 0.3
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0.2 List of effective pages
Section page issued replaced / replaced / replaced /
0 0.0 December 09
0.1 See manual amendments
0.2 See manual amendments
0.3 See manual amendments
0.4 See manual amendments
0.5 See manual amendments
0.6 See manual amendments
0.7 December 09
0.8 "
0.9 " July 11 September 11
0.10 "
0.11 "
1.1 December 09
1.2 "
1.3 "
1.4 "
1.5 "
1.6 "
1.7 "
1.8 "
1.9 "
1.10. " September 11
1.11 "
1.12 "
1.13 "
1.14 "
1.15 "
1.16 "
1.17 "
1.18 "
1.19 "
1.20 "
1.21 "
1.22 "
1.23 "
1.24 "
1.25 "
1.26 "
1.27 "
1.28 "

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 0.4
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
List of effective pages (cont.)
Section page issued replaced / replaced / replaced /
1.29 December 09
1.30 "
2 2.1 December 09 September 11
2.2 "
2.3 " September 11
2.4 "
2.5 "
2.6 " September 11
2.7 "
2.8 " September 11
2.9 " September 11
2.10 "
3 3.1 December 09
3.2 "
3.3 "
3.4 "
3.5 "
3.6 "
3.7 "
3.8 "
3.9 "
4 4.1 December 09
4.2 "
4.3 "
4.4 "
4.5 " September 11
4.6 " September 11
4.7 "
4.8 "
4.9 "
4.10 "
4.11 "
4.12 "
4.13 "
4.14 "
4.15 "
4.16 "
4.17 "

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 0.6
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
List of effective pages (cont.)
Diagram issued replaced replaced replaced replaced
1 April 90
2 April 90
3 April 90
4 April 90
5 April 90
6 April 90
7 April 90
7a July11
8 April 90
9 April 90
10 April 90
11 March
97
12 April 90
13 Febr. 96
14 April 90 May 08
Enclosures issued replaced replaced replaced
(9.1) Equipment list Dec. 09
(9.2) Checklists for the 25
hour service work Dec. 09
5EP30 Installation ELT 27.02.91
5EP31 Installation Dräger
oxygen system 5.02.90
5E1 Wiring scheme 09.04.90
5E2 Wiring plan 08.03.90
Service Info 0-2/92 Mar. 92
Working instruction No. 1 for
TN348/20 issue 3 22.10.08

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 0.9
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
Sectioncontent page
6
Instrumentation and accessories list ........................................................6.1
6.1 Air speed indicator (0 - 300 km/h, 165 kts).............................................6.1
6.2 Altimeter ..................................................................................................6.1
6.3 Harness (seat)...........................................................................................6.1
6.4 Compass...................................................................................................6.2
6.5 VHF transceiver.......................................................................................6.2
6.6 Variometer ...............................................................................................6.2
6.7 Turn and bank indicator...........................................................................6.3
6.8 Engine instrumentation............................................................................6.3
6.9 Engine elapsed - time indicator ...............................................................6.3
6.10 Instruments which are not part of the minimum equipment:...................6.3
7 List of special tools..................................................................................7.1
8 Partlist ......................................................................................................8.1
8.1 Parts for the power plant..........................................................................8.1
8.2 Parts for the electrical system..................................................................8.2
Diagrams
1 Elevator control circuit, trim
2 Rudder control circuit
3 Controls in the fuselage (aileron, wing flaps and airbrakes)
4 Controls in the wings (aileron, wing flaps and airbrakes)
5 Tow hooks
6 Waterballast system
7 Landing gear, hydraulic wheel brake (wheels ser. No. up to ser. No. 51841
except for 51833)
7a Landing gear, hydraulic wheel brake (wheels from ser. No. 52002 on and
51833)
8 Pitot static system
9 Placards
10 Steerable nose wheel
11 Power plant
12 Power plant
13 Extension-retraction mechanism
14 Fuel system
Enclosures
(9.1) Equipment list
(9.2) Checklists for the 25 hour service work
5EP30 Installation ELT
5EP31 Installation Dräger oxygen system
5E1 Wiring scheme DIN A 2 (in aircraft log)
5E2 Wiring plan DIN A 1 (in aircraft log)
Service Info 0-2/92, engine test run
Working instruction No. 1 for TN348/20 issue 3, headrest securing ropes

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 1.10
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
1.6.1.4 Hydraulic brake system
a) Brake fluid approved specification DOT 3, DOT 4, SAEJ 1703.
The brake fluid must be exchanged at least every 4 years.
Warning: brake fluid is poisonous
b) Adjustment: see section 1.5.2 c)
If adjustment does not increase the braking effect as desired, the
brake system is leaking or there is air in the brake system. Bleeding of
the brake system see section 4.5.
c) The brake linings must be replaced if they are used up to a thickness
of 2.5 mm (0.098 in.). Removal of brake calliper see sect. 4.4 B.
Replacement set (2 linings, 6 rivets) Tost No. 075860
d) The brake disc must be replaced if it is used up to a thickness of 4.2
mm (0.167 in.). Removal of the wheel see sect. 4.4 A.
1.6.2 Steerable nosewheel
1.6.2.1 Control system see diagram 10
The nose wheel is connected to the rudder control with springs.
1.6.2.2 Adjustment of the spring tension
The adjustment is made at the rear rudder pedals. Adjust so that the
springs are just untensioned.
1.6.3 Tyre pressure
Main wheel3 bar (44 psi)
Nose wheel 2.5 bar (36 psi)
Tail wheel 4 bar (58 psi)

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 2.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
2Inspections
2.1 Daily inspection
see flight manual DG-500M.
2.2 Regular inspections
A) After 200 flight hours and during the annual inspection
Check the rudder cables for wear especially around the “S” tubes on the
rudder pedals. Worn rudder cables should be replaced (see section 4.2).
Check the sealing of the rudder (see section 1.3.5).
B) Annual inspection (and 100hr inspection – only for USA)
•Execute all items of the daily inspection (see flight manual section 4.3).
Check especially the headrest securing ropes in the rear cockpit
according to “Working instruction No. 1 for TN348/20 issue 3”
(attached to this manual) for correct assembly and for wear.
•Check all control circuits: Inspect all bolted connections and locking
devices ie. locknuts, split pins etc.
•Check all control circuits for adequate greasing and rust prevention. (see
section 3.3).
•Check the control surface deflections (see section 1.2 - 1.4).
•Check the free play in all control circuits (see section 1.2 - 1.6) and the
fore and aft play of the wings (see section 1.10).
•Check the canopy emergency release (see flight manual section 7.15).
•Check the rubber cords in the control system (see section 1.2.6, 1.4.6
and 1.7.5).
•Check the thickness of the wheel brake linings and the thickness of the
wheel brake disc (see section 1.6.1.4).
•Check if the wheel brake fluid has been exchanged (see section 1.6.4).
•Check the complete power plant.
•Check the friction brake of the throttle control (see section 1.11.8).
•Propeller
You have to dismount the propeller for inspection especially for cracks
at the hub boss. After reassembling the propeller you should check the
blade track see section 3.5 of the propeller manual. After the first flight
after reassembling the propeller, you have to check the torque of the
propeller bolts again see section 3.5.1 item 33 of this manual.
•Tow hook
The operating and maintenance instructions for the release mechanisms,
see section 0.4 of this maintenance manual have to be followed.
•All-up weight and centre of gravity These should be checked at least
every 4 years during the yearly inspection.

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 2.3
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
b) Inspection after rigging
Walk around the aircraft
1. All parts of the airframe
a) check for flaws such as bubbles, holes, bumps
and cracks in the surface
b) check leading -and trailing edges of the wings and control surfaces for
cracks
2. Cockpit area
a) check the canopy locking mechanism
b) check the canopy emergency release see section 7.15 flight manual
c) check the main pin securing
Check especially the headrest securing ropes in the rear cockpit according
to “Working instruction No. 1 for TN348/20 issue 3” (attached to this
manual) for correct assembly and for wear.
d) check all controls for wear and function, incl. positive control check
e) check the tow release system for wear and function incl. cable release
check
f) check for foreign objects
g) check the instrumentation and radio for wear and function
h) check the brake fluid level
i) check the fuel filter for dirt and sludge
j) check the engine controls
k) check all fuses including the battery fuse
l) check the extension-retraction mechanism by operating it in both
directions. The extension time should not exceed 13 seconds!
Note: If the mechanism can't be operated with the ignition switch or with the
manual switch, check the circuit breaker.
m) extend the engine with the manual switch
3. C.G. Tow hook
a) check the ring muzzle of the C.G. hook for wear and function
b) check for cleanliness and corrosion
4. Main landing gear and nose wheel
a) check the struts, the gear box, the gear doors and the tyre for wear; dirt in
the struts can hinder the landing gear from locking over center the next time!

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 2.6
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
C) Every 3 months
Check the tension of the lines of the waterbag attachment (see section
4.1.).
D) Special inspections
Tow hook
After a wheel-up landing, the C.G. tow hook is to be cleaned. Check tow
hook and tow hook bulkheads carefully for any damage.
C.G. weighing: After all work which may influence the C.G.
Propeller
In addition to the instructions given in the propeller manual you have to
check the torque of the propeller bolts if you operate your aircraft in
varying temperature and humidity conditions. Especially high ambient
temperature and low humidity are likely to cause shrinkage of the
wooden propeller and thus loss of torque (pre-tension) which may lead to
failure of the propeller bolts. To check see section 3.5.1 item 33 of this
manual.

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 2.8
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
Fuselage cont.
Tailplane attachment:
Increased free play? Cracks in the fin top rib? Check if the aluminium parts
of the tailplane attachment are bent or loose, check the tailplane locking
device
Rudder mounts:
Increased free play? White areas in the glass fibre, bent rudder hinge pin
supports?
Fuselage skin:
outside: cracks, nicks, folds? Any separation of the skin from the core?
inside: white spots, zig zag white lines, cracks? Has any bulkhead become
loose?
C.G. tow release:
Especially after a wheel up landing, check for dirt etc., check for proper
functioning. Has the tow release housing become detached from the
fuselage?
Seat back bulkhead:
Cracks? Shoulder strap attachment points?
Belly harness attachment points:
Check for cracking around the mountings in the seat. Check the safety
harness assembly.
Controls:
Check for proper functioning and condition of all controls and adjustment
mechanisms (i.e. rudder pedal adjustment, tow release, air brake, control
column and trim etc.).
Instruments:
Proper functioning? Dirt in the static ports or in the pitot probe?
Engine compartment:
Check for damage of the walls.
Does the engine retract without scratching the side walls?
Do the engine doors close as well as before?

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 2.9
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
Landing gear :
Check to insure if properly aligned? No bent forks? Proper extension and
retraction? Any dirt in the forward fork pivot? Any white areas or cracks in
the wheel box? Remove the baggage area floor panels and inspect the
wheel box from above. Landing gear control circuit condition. Is there free
play between actuating lever and rear upper fork?
Nose wheel and tail wheel
Any cracks or white patches around the attachment?
Check the steerable nose wheel for bent struts, damaged bearings and easy
motion.
Horizontal tailplane-stabilizer:
Outer skins: Crushing, cracks, delaminations?
Mounting: Glued joint of the bushes, white areas around bushes, cracks in
shear webs, cracks around locking plate?
Hinge mounts: checked?
Elevator:
Crushing, cracks, delaminations?
Hinge mounts checked? - Control surface horn bent or loose?
Do all checks of the daily inspection (see flight manual section 4.3).

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 4.5
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
4.5 Filling and bleeding the hydraulic disc brake
Note: The master cylinder is mounted in an upright position. This means that
filling and bleeding the system is only possible from the lowest point, which is
the brake cylinder assembly at the wheel.
Necessary tools:
1 open-end wrench 1/4" = 6.35 mm for the bleeder valve at the brake
calliper.
1 open-end wrench 11/16" = 18 mm.
2 Plastic syringes acid resistant, volume approx. 100 ml (6 cu.in.). Use this
syringe for brake fluid only! 1 bleeder assy Tost No. 075890.
1 m (3 ft.) transparent PVC hose inside diameter 8 mm (0.31 in.), fixed to
syringe and bleeder assy with hose clamps.
Brake-fluid DOT 3, DOT 4 or SAEJ 1703.
1. Preparations
-Raise the fuselage, extend the landing gear.
-Fix left wheel door in the fully open position.
-Set the airbrake control in the retracted position.
-Remove the baggage compartment floor and rear cover, check that the
actuating cable for the master cylinder is loose and if the piston rod of
the master cylinder is at its upper stop.
-Remove the main wheel according to section 4.4 A. Place the wheel so
that the brake hose makes no bow above or below the horizontal. If
necessary lift the fuselage even more.
2. Filling (empty system)
Warning: Brake fluid is poisonous! Protect your hands and clothes. Remove
all spilled brake fluid. Clean all parts which had contact with brake fluid with
alcohol, don't use fuel or solvents.
-Remove the cap and the membrane from the reservoir.
-Fill the first syringe (with hose and bleeder assy.) with brake fluid,
eliminate all air bubbles.
-Remove the protection cap from the bleeder valve at the brake calliper,
attach the bleeder assy. and fix it with the 11/16" wrench.
-Open the bleeder valve at the cylinder assy, use the 1/4" wrench, fill in
slowly the complete volume avoiding air bubbles.
-Fill the complete system up to 15 mm (0.6 in.) below the upper edge of
the reservoir, avoid over filling.
-Close the bleeder valve at the brake calliper.
-Use the second syringe to remove all brake fluid from the reservoir.

Maintenance Manual DG-500M
Issued: September 2011 TN500/05 4.6
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
-Fill the first syringe again, open the bleeder valve and fill in further
brake-fluid. Look at the reservoir while filling to see if air bubbles are
coming out of the line. Fill up to 15 mm (0.6 in.) below the upper edge
of the reservoir.
-Close the bleeder valve, reinstall the membrane and the cap to the
reservoir and remove the bleeder assy.
-Check brake pressure according to step 3..
-Reinstall the main wheel.
3. Check brake pressure:
-Extend the airbrakes, there must be a strong pressure when the wheel
brake engages.
-Check several times, the wheel brake must engage at the same point
every time
-If this is not the case, you have to bleed the system again, see step 5..
4. Check the hydraulic brake system for leaks:
Extend the airbrakes with high force and hold it in this position for 2
minutes.
Then check the whole hydraulic system visually for leaks. If necessary
tighten the screwed joints or replace the sealings and bleed the system
again.
Note: The adjustment of the length of the cable between the master cylinder and
the airbrake control shaft restricts the max. airbrake extension height. The
adjustment of this cable should be done with the glider rigged.
5. Bleeding the hydraulic brake system
Remove the brake fluid from the reservoir using the syringe.
Then execute again steps 2 and 3 of this instruction.
6. Exchanging brake fluid (every 4 years)
-Perform preparations (see step 1.) of this instruction. It is not
necessary to remove the main wheel.
-Fill the system with new brake fluid (see step 2.). To accomplish this
remove all brake fluid from the reservoir first with the second syringe.
Used brake fluid is darker than new brake fluid and can easily be
identified. Watch the reservoir while filling to see when the new fluid
streams into the reservoir. Repeat the filling process until only new
fluid is in the system and no air bubbles can be detected.
-Perform steps 3. and 4. of this instruction.