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. [phone]  Telefax 07251/3020-200  eMail: [email protected]
Spare part and material sales: Tel. [phone]  [email protected]
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

Maintenance Manual DG-808C
Issued: July 2017 TN800/45 0.1
0 General
0.1 Manual amendments
No. Page Description Date
1 0.3, 0.6, 0.10, 1.11, 8.2,
diagrams 5a, 11d, 8EP210
ÄM 800-17-07
Fin tank valve and operating
handle, Refuelling pump
April 2007
2 0.3, 0.4, 0.6, 0.7, 0.10, 0.12,
1.28, 1.29, 2.7, 3.3, 3.5, 3.11,
4.2, 4.8, 4.11, encl. 2 page 1,
TN 4600-2-2 Solo
TN800/34
Manual revision
September
2007
3 0.6, 8.1, diagram 10 TN800/35
Extension-retraction unit, rear
fork of spindle-drive
April 2009
4 0.3 ÷ 0.12, 1.3, 1.5, 1.6, 1.8,
1.10, 1.11, 1.14 ÷ 1.16, 1.24,
1.27, 1.29, 1.30, 2.1, 2.2, 2.6,
2.7, 3.1, 3.3 ÷ 3.11, 4.1 ÷ 4.3,
4.6 ÷ 4.11, 4.13, 4.15, 4.16,
4.18 ÷ 4.23, 4.25 ÷ 4.31, 5.1,
5.2, 6.1 ÷ 6.3, 7.2, 8.1 ÷ 8.4,
9.2,
diagrams 1 ÷ 5, 5a, 8, 9, 10, 11,
11d, 12, 13, 13b, 14, 17,
14a removed,
8M110, 8E250, SI 69-10
TN800/41
Manual revision,
Coolant pump Pierburg
May 2012
5 0.0, 0.1, 0.3 - 0.6, 0.11, 0.12,
2.1, 2.2, 3.7, 4.33, 8.1 - 8.3,
diagrams 3, 9,
8E250h, 8E256b
manual revision,
TN800/45
July 2017

Maintenance Manual DG-808C
Issued: June 2005 0.2
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Maintenance Manual DG-808C
Issued: July 2017 TN800/45 0.3
0.2 List of effective pages
Section page issued replaced/ replaced/ replaced/
0 0.0 June 2005 July 2017
0.1 see manual amendments
0.2 "
0.3 "
0.4 "
0.5 "
0.6 "
0.7 June 2005 Sept. 2007 May 2012
0.8 " May 2012
0.9 " May 2012
0.10 " Sept. 2007 May 2012
0.11 " May 2012 July 2017
0.12 " Sept. 2007 May 2012 July 2017
1 1.1 June 2005
1.2 " May 2012
1.3 " May 2012
1.4 "
1.5 "
1.6 " May 2012
1.7 "
1.8 " May 2012
1.9 "
1.10 " May 2012
1.11 " April 2007 May 2012
1.12 "
1.13 "
1.14 " May 2012
1.15 " May 2012
1.16 " May 2012
1.17 "
1.18 "
1.19 "
1.20 "
1.21 "
1.22 "
1.23 "
1.24 " May 2012
1.25 "

Maintenance Manual DG-808C
Issued: July 2017 TN800/45 0.4
0.2 List of effective pages (continued)
Section page issued replaced/ replaced/ replaced/
1.26 June 2005
1.27 " May 2012
1.28 " Sept. 2007
1.29 " Sept. 2007 May 2012
1.30 May 2012
2 2.1 June 2005 May 2012 July 2017
2.2 " May 2012 July 2017
2.3 "
2.4 "
2.5 " May 2012
2.6 " May 2012
2.7 " Sept. 2007
3 3.1 June 2005 May 2012
3.2 "
3.3 " Sept. 2007 May 2012
3.4 " May 2012
3.5 " Sept. 2007 May 2012
3.6 " May 2012
3.7 " May 2012 July 2017
3.8 " May 2012
3.9 " May 2012
3.10 " May 2012
3.11 " Sept. 2007 May 2012
4 4.1 June 2005 May 2012
4.2 " Sept. 2007 May 2012
4.3 " May 2012
4.4 "
4.5 "
4.6 " May 2012
4.7 " May 2012
4.8 " Sept. 2007 May 2012
4.9 " May 2012
4.10 " May 2012
4.11 " Sept. 2007 May 2012
4.12 "
4.13 " May 2012
4.14 "
4.15 " May 2012
4.16 " May 2012

Maintenance Manual DG-808C
Issued: July 2017 TN800/45 0.5
0.2 List of effective pages (continued)
Section page issued replaced/ replaced/ replaced/
4.17 June 2005
4.18 " May 2012
4.19 " May 2012
4.20 " May 2012
4.21 " May 2012
4.22 " May 2012
4.23 " May 2012
4.24 "
4.25 " May 2012
4.26 " May 2012
4.27 " May 2012
4.28 " May 2012
4.29 " May 2012
4.30 " May 2012
4.31 " May 2012
4.32 "
4.33 " July 2017
4.34 "
4.35 "
4.36 "
4.37 "
4.38 "
5 5.1 June 2005 May 2012
5.2 " May 2012
6 6.1 June 2005 May 2012
6.2 " May 2012
6.3 " May 2012
7 7.1 June 2005
7.2 June 2005 May 2012
8 8.1 June 2005 May 2012 July 2017
"
8.2 " May 2012 July 2017
8.3 " May 2012 July 2017
8.4 " May 2012
9 9.1 June 2005
9.2 " May 2012

Maintenance Manual DG-808C
Issued: July 2017 TN800/45 0.6
0.2 List of effective pages (continued)
diagram issued replaced/ replaced/ replaced/
1 June 2005 May 2012
2 June 2005 May 2012
3 Nov. 2004 May 2012 July 2017
4 Nov. 1993 May 2012
5 Nov. 2004 May 2012 valid up to ser. No. 8-372
5a April 07 May 2012 valid from ser. No. 8-373 on
6 May 2005
7a August 2005
7b August 2005
8 August 2005 May 2012
9 August 2005 May 2012 July 2017
10 August 2005 April 2009 May 2012
11 Juni 2005 May 2012 valid up to ser. No. 8-372
11c June 1999
11d April 07 May 2012 valid from ser. No. 8-373 on
12 June 2005 May 2012
13 Febr. 1999 May 2012
13a May 2012
14 Nov. 2004 May 2012
14a June 2005 May 2012 no more effective
15 Nov. 2004
16 Nov. 2004
17 May 2012
6EP27M 28.08.90
8EP38 17.02.99
8EP210 12.02.07
8M110 23.10.02 5.07.11
8M234 25.08.05
8V96 19.12.94
W40 30.11.99
W51 20.11.96
W57 10.09.99
W59 18.06.02
W60 25.10.04
8E25 25.06.99
8E210 15.05.97
8E250 13.09.05 18.10.11 15.01.14 Valid from
ser.no. 8-428 on
without 431
8E256 24.06.05 15.01.14 Valid from ser.no. 8-428 on
without 431
Encl. 1 June 2005
Encl. 2 Sept. 2007
TN 4600-
2-2 Solo
Jan. 2007
SI 69-10 14.05.10

Maintenance Manual DG-808C
Issued: May 2012 TN800/41 0.7
0.3 List of content
Section content page
0 General 0.1
0.1 Manual amendments .............................................................................. 0.1
0.2 List of effective pages ............................................................................ 0.3
0.3 List of 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 equipment and components ............................... 0.11
0.4.4 Service time, maintenance documents of equipment and
components ............................................................................................ 0.12
0.4.5 Power plant trouble shooting ................................................. 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
1.3 Rudder control ........................................................................................ 1.5
1.4 Aileron and wing flap control ................................................................ 1.6
1.5 Airbrake control, wheelbrake ................................................................. 1.8
1.6 Undercarriage ......................................................................................... 1.9
1.7 Tow hooks ............................................................................................ 1.10
1.8 Water ballast system ............................................................................ 1.11
1.9 Massbalance and weights of control surfaces ...................................... 1.12
1.10 Fore and aft play of the wings.......................................................... 1.13
1.11 Power Plant ...................................................................................... 1.14
1.11.1 Arrangement: ......................................................................... 1.14
1.11.2 Engine type, coolant .............................................................. 1.14
1.11.3 Exhaust Muffler: .................................................................... 1.14
1.11.4 Propeller: ................................................................................ 1.15
1.11.5 Drive Belt: .............................................................................. 1.15
1.11.6 Starter: .................................................................................... 1.15
1.11.7 Ignition system: ...................................................................... 1.15
1.11.8 Throttle cable connections ..................................................... 1.15
1.11.9 Propeller brake ....................................................................... 1.16
1.11.10 Tightening torques and locking: ............................................ 1.16
1.11.11 Fire warning light ................................................................... 1.16
1.12 Retraction - Extension Mechanism .................................................. 1.17
1.13 Fuel system ...................................................................................... 1.18
1.14 Electrical system .............................................................................. 1.23
1.15 Pitot and static system ...................................................................... 1.30
1.16 Ventilation and drain holes .............................................................. 1.30

Maintenance Manual DG-808C
Issued: May 2012 TN800/41 0.8
Section content page
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
2.5 Inspection procedure for the controls .................................................... 2.7
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 Servicing the Engine .............................................................................. 3.5
3.5.1 25 hour inspection .................................................................... 3.5
3.5.2 With every annual inspection ................................................ 3.11
3.5.3 After 50 resp. 100 engine hours ............................................. 3.11
3.5.4 After 400 engine hours .......................................................... 3.11
3.5.5 After 6 years ........................................................................... 3.11
3.5.6 When required ........................................................................ 3.11
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 Removal and installation of the undercarriage (main wheel) ................ 4.3
4.4.1 General ..................................................................................... 4.3
4.4.2 Removal ................................................................................... 4.3
4.4.3 Installation ............................................................................... 4.3
4.4.4 Filling and bleeding the hydraulic disc brake (Option) ........... 4.4
4.5 Fixing excessive free play of the canopy ............................................... 4.6
4.6 Removal and installation of the flaperons ............................................. 4.7
4.7 Control surface seals and turbulators ..................................................... 4.8
4.8 Determination of the moments of the flaperons .................................. 4.12
4.9 Working instructions for heat-shrink tubing ........................................ 4.13
4.10 Securing with Loctite ....................................................................... 4.13
4.11 Replacement of wing fuel tanks (Option) ........................................ 4.14
4.12 Mounting and tensioning of the drive belt ....................................... 4.15
4.13 Replacing the bearings of the upper drive belt pulley ..................... 4.18
4.14 Removal and installation of the tension gas-strut ............................ 4.20
4.15 Replacement of the engine retaining cable ...................................... 4.21
4.16 Filling and bleeding the cooling system, checking the coolant pump4.22

Maintenance Manual DG-808C
Issued: May 2012 TN800/41 0.9
Section content page
4.17 Installation and removal of the powerplant ..................................... 4.24
4.18 Removal and assembly of the engine doors..................................... 4.31
4.19 Securing the propeller bolts ............................................................. 4.32
4.20 Checking the Ignition unit ............................................................... 4.33
4.21 Installation and removal of the extension/retraction unit ................ 4.36
4.22 Calibration of the fuel display in the DEI-NT ................................. 4.37
4.23 Further DEI-NT settings .................................................................. 4.37
5 Weight and balance 5.1
6 Instrumentation and accessories list 6.1
7 List of special tools 7.1
8 Partlist 8.1
8.1 Parts for the powerplant ......................................................................... 8.1
8.2 Parts for the electrical system ................................................................ 8.3
8.3 Control surface sealings 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-808C
Issued: May 2012 TN800/41 0.10
Diagrams
1 Elevator control circuit, trim
2 Rudder control circuit
3 Aileron, wing flap and airbrake control circuits, fuselage side
4 Flaperon and airbrake control circuits, wing side
5 Tow hook, water ballast system
5a Tow hook, water ballast system from ser. no. 8-373 on
6 Static and pitot system
7a Placards DG-808C Classic
7b Placards DG-808C Competition
8 Powerplant
9 Cooling system
10 Extension-retraction mechanism
11 Fuel system
11c Installation of the fuel filter
11d Fuel system from ser. no. 8-373 on
12 Tailwheel
13 Propellerbrake
13b Propellerbrake with modified mounting of the propeller-brake retaining
rubber cord (Option TN 800/41)
14 Engine doors and retaining cable
14a Retaining cable mounting in fuselage no more effective TN 800/41
15 Undercarriage control circuit
16 Undercarriage
17 Drain and ventilation holes
Enclosures
6EP27M Installation Dräger oxygen system
8EP38 Installation plan ELT ACK
8EP210 wing fuel tank system fuselage side with electromagnetic valves
8M110 Drawing assembly upper drive belt pulley
8M234 Ext.-retr. unit, installation propeller stopper Option BBSA clutch
8V96 Drawing jigs to determine the static moment of the flaperons
W40 Puller assy. for lower drive belt pulley
W51 Drawing hook spanner for bearings
W57 Tool for measuring the drive belt tension
W59 Test adapter for coolant pump test
W60 Puller assy. for lower drive belt pulley Option BBSA clutch
8E25 Wiring plan wing fuel tank system fuselage side with electromagnetic
valves
8E250 Wiring plan DIN A1 (in aircraft log)
8E256 Wiring scheme
8E210 Extension wires for checking the ignition electronic boxes
Encl. 1 Download instruction for flightlog and service data from the DEI-NT
Encl. 2 Instructions for transponder installation
TN 4600-2-
2 Solo
Check and modification of the slip-clutch on the engines 2 625 01 and 2
625 02
SI 69-10 Service Info: Adjustment of propeller after jump of drive belt

Maintenance Manual DG-808C
Issued: July 2017 TN800/45 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-800B repair manual for repairs of the airframe.
Repairs exceeding those as defined as minor damage in the DG-800B repair
manual section 2 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 the variant DG-808C is 12000 flight
hours. Therefore inspections according to section 2.4 of this manual have to be
executed at 3000 h, 6000 h, 9000 h and every 1000 hours following thereafter.
0.4.3 Life time of equipment and components
Use only genuine spare parts. For part. No.’s of all parts please refer to section 8.
a) The following components of the power plant have to be replaced after
400 engine hours.
1. All nuts and bolts on the engine (part No. 39001025)
2. The bearings of the upper drive belt pulley (part No. 59332050 and
59320320)
b) The gasket for the drainer valve (part No. 60504402) has to be exchanged
after 6 years.
c) The coolant hoses (part no. 39001017 resp. 18) have to be exchanged after
6 years.
Note: The coolant (type see section 1.11.2) has to be exchanged after 6 years.
d) Drive belt (part. No. 60504012):
Without optional BBSA friction/centrifugal clutch: The drive belt has to be
exchanged after 50 engine hours.
With optional BBSA friction/centrifugal clutch: The drive belt has to be
exchanged after 100 engine hours
e) Limitation for drive belt rollers no more applicable.
f) The spark plugs (part. No. 40050360) have to be exchanged after 25 engine
hours.

Maintenance Manual DG-808C
Issued: July 2017 TN800/45 0.12
f) 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.
g) Flexible fuel bags in the wings (option)
Type Uniroyal (rubber): these will have to be exchanged after 10 years.
Type HFK (plastic): see Mounting and testing instructions for HFK
TLF.
Note: The brake fluid of the wheel brake (Option) has to be exchanged after 4
years (types see section1.6.4).
Note: All other components like 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.
0.4.4 Service time, maintenance documents of equipment and
components
Follow the instructions of the respective manufacturer:
a) Operating Manual for Safety Tow Releases
Series: Europa G 88 Safety Tow Release
latest approved version.
And if installed:
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 6.3.
c) Minimum instrumentation: instructions of the manufacturer.
Approved types see section 6.1, 6.2 and 6.4.
d) Engine: Manual of the engine manufacturer latest approved version.
e) Propeller: Technoflug Operation and maintenance manual No. P3 latest
approved version.
0.4.5 Power plant trouble shooting
Please find a checklist in the DG-808C flight manual section 8.8.
Note: 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.
approved

Maintenance Manual DG-808C
Issued: June 2005 1.1
1 System description and adjustment data
1.1 Wing and tailplane setting data
Wing:
Sweep back (Leading edge): 0 + 3 mm (+ 0.12 in.) at wing taper change
Dihedral (Leading edge line): 2.5° = 196 mm (7.72 in.) at wing taper
change (y = 4.5 m)
Angles of Incidence: -1° measured at wing flap setting -5°
Horizontal tailplane:
Angles of Incidence -3,5°
chord lines
fuselage centre line
(corresponding to boom slope 1000:37)
Wing oscillation
frequency:
approx. 160/min 15 m span with winglets
approx. 130/min 18 m span without parting
approx. 124/min 18 m span with parting and
winglets
Aircraft should rest on both wheels during frequency measurements.
1° 3,5°

Maintenance Manual DG-808C
Issued: June 2005 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: 46 + 2 mm 1.81 + 0.08 in.
down: 46 + 2 mm 1.81 + 0.08 in.
measured at 134 mm (5.3 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. Deflect the elevator to neutral
position by bringing the mark at the sealing in line with the upper end of the fin.
Mark the 0-point on the stick. Then mark the up and down displacement.
measuring stick one end on the floor
462 mm
462 mm
sealing mark

Maintenance Manual DG-808C
Issued: May 2012 TN800/41 1.3
1.2.3 Elevator stops
The elevator stops are located at the base of the control column and can be
adjusted with a 10 mm open ended spanner.
1.2.4 Elevator control circuit free play
With the elevator held fixed at the 0 point, the free play at the top of the control
column can be +1.5 mm (+0.06 in.). Within the automatic elevator connection
there should be no free play noticeable 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 automatic trim mechanism should be adjusted according to the sketch
below. The measurements a and b are with the control stick in forward position:
a = 30 mm (1.18 in.), b = 187 mm (7.36 in.), c = 357 mm (14.1 in.).
The bungee interconnection between wing flap lever 6St9 and trim lever 2St32
is to be replaced, when worn or when elongated. The length in unstretched
condition y must be 110 mm (4.3 in.). The interconnection consists of 2 mm
diameter. bungee wound around 3 times.
locking nut
adjustment screw
elevator
y
6St9
2St32 2St32
a b
c
bulkhead

Maintenance Manual DG-808C
Issued: June 2005 1.4
1.2.6 Repair of the automatic trim mechanism Bowden cable
In the event of a replacement Bowden cable being installed, it should be
emphasised that the cable must pass between the two parallel arms of the
Control column mechanism as shown in the sketch.
correct
wrong
If the cable passes outside the mechanism
control column movement can be blocked.

Maintenance Manual DG-808C
Issued: May 2012 TN800/41 1.5
1.3 Rudder control
1.3.1 Rudder control circuit
see diagram 2
1.3.2 Rudder deflections and tolerances
155mm (6.5 inch) (28°) +0, -5mm (-.2 inch) measured at 318 mm (12.52 inch)
from the hinge axis.
1.3.3 Rudder stops
The rudder stops are located at the lower hinge pedestal and can be adjusted
with an Allen key wrench.
1.3.4 Axial free Play
The maximum allowable free play at the upper hinge point is 1.5 mm (0.06 inch)
1.3.5 Sealing the rudder
The rudder is sealed on both sides. On the outside with Mylar combi-tape and
inside the fin with V-sealing tapes
These sealings are not to be removed.
If damaged it should be replaced, see section 4.7.6
1.3.6 Retaining spring for the pedal adjustment handle
A spring which pulls the pedal adjustment cable tight is installed in the console
below the instrument panel. If this spring is defective or not connected 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.
max. 1,5 mm

Maintenance Manual DG-808C
Issued: May 2012 TN800/41 1.6
1.4 Aileron and wing flap control
1.4.1 Control circuit
see diagrams 3 and 4
A spring at the mixer shaft 8St70 provides additional aileron return force at
positive wing flap settings.
Note: The bearing of 6St9 on 6St15 see diagram 3 must not be greased (Teflon
bearing).
1.4.2 Deflections and tolerances
Aileron deflections: up 42 ± 3 mm 1.65 + 0.12 in.
down 21 ± 3 mm 0.83 + 0.12 in.
measured at 122 mm (4.8 in.) from hinge axis (at inboard end), wing flap
setting -5°.
Wing flap deflections: up -14° 19 ± 3 mm (-0.75 + 0.12 in.)
down L 38 ± 3 mm +1.50 + 0.12 in.)
measured at 122 mm (4.8 in.) from hinge axis against the fixed part at the wing
root.
At flap setting -5° the flaperons have to be adjusted against the fixed part at the
wing root with 0 + 1 mm (0 + 0.04 in.).
1.4.3 Stops
The aileron stops are located behind the removable left-hand side panel. The
stops can be adjusted at the nuts on the pushrod with two 4 mm (5/32 in.)
diameter rods or drills.
The wing flap stops are located at the pushrod 6St8.
The stop for the positive setting (welded washer at pushrod 6St8 with
Nylonbush) is at the seatback bulkhead. Adjustment by displacing pushrod 6St8
against the rear pushrod 6St7.
The stop in negative setting is a hose clamp which stops at the leaf-spring 8St4.
1.4.4 Free play
The max. free play measured at the trailing edge of the flaperons measured at
122 mm (4.8 in.) from hinge axis should not exceed +1 mm (+0.04 in.) The
control stick and the wingflap should be in neutral position.
For the measurement fix the flaperon of the opposite wing. With both flaperons
fixed, a maximum free play of +1.5 mm (+0.06 in.) at the top of the control stick
is allowed.

Maintenance Manual DG-808C
Issued: June 2005 1.7
1.4.5 Complete readjustment
Should it be necessary to completely reset the flap and aileron control, proceed
as follows:
Place the fuselage with the centre line horizontal see sect. 1.1. Fix the mixer
shaft 8St70 (see diagram 3) in horizontal position.
then:
1. Adjust the control stick to neutral.
2. Adjust the wing flap handle to 0° flapsetting.
3. Adjust the flaperons: + 10.6 mm (0.42 in.) measured against the fixed part at
the wing root and + 4.1 mm (0.16 in.) against the 18 m wing tip.
To adjust the flaperons you must first remove the fairings from the control
surface horns. Then unscrew the horns (Allen key wrench) and loosen the lock
nut (12 mm open ended wrench) at the rod ends. Adjustment is made by rotating
the complete drive.
Caution: Secure the bolts again with a small amount of Loctite 243.
4. Adjust the aileron stops. (See 1.4.3)
5. Check the flap deflections and adjust the stops if necessary. (See 1.4.3)
6. Glue the fairings to the control surface horns with Polyester resin. Apply
pressure when gluing to prevent the fairings interfering.
horizontal
8St70