DG Flugzeugbau LS8 Series User manual

Maintenance Manual LS8
Issued: December 2009
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0-0
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 of the maintenance manual.
Yours sincerely
DG FLUGZEUGBAU GMBH
Dipl.- Ing. W. Dirks

Maintenance Manual LS8
Issued: June 2016 TN8024
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0-1
0General
0.1 Manual amendments
No Page Description Date
0.1 all Combination of the initial
Maintenance Manuals of the
Variants LS8, LS8-a, LS8-b,
LS8-18, new standardized format
Dec. 2009
0.2 0-9, 1-15, 1-16, 2-3, 2-5, 3-
2, 3-3, 3-6, 4-12, 4-13, 4-15
up to 4-17, 5-2, 5-3, 5.4, 6-1,
9-1 up to 9-4, 10-1 up to 10-
3, 11-1, 11-2, 12-2, 12-3
Miscellaneous changes to the
contents of the latest amendments
of the initial maintenance
manuals
Dec. 2009
1 0-1, 0-3, 0-5, 1-1, 1-6,
1-10, 7-5, 7-6
TN8019, wheel brake actuated by
airbrake handle.
Feb. 2011
2 0-1, 0-3, 0-5, 1-11, 7-1, 7-2,
7-4, 8-3 and 12-1
TN8020, retrofit of a 5” landing
gear
Sept. 2011
3 0-1, 0-3, 0-5, 7-1 ÷ 7-4 TN 8021
Small tailwheel
January
2015
4 0-1, 0-3 ÷ 0-5, 0-9, 2-2, 2-3,
2-5, 3-1, 4-4, 5-2, 5-6, 5-7,
7-1 ÷ 7-4, 7-6, 9-1, 9-2, 10-1
TN 8024
Manual revision, repair manual
June 2016

Maintenance Manual LS8
Issued: December 2009
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Maintenance Manual LS8
Issued: June 2016 TN8024
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0-3
0.2 List of effective pages
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Maintenance Manual LS8
Issued: June 2016 TN8024
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0-4
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Maintenance Manual LS8
Issued: June 2016 TN8024
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0-5
0.2 List of effective pages (continued)
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5-2 " June 2016
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6 6-1 December 09
7 7-1 " Sept. 2011 Jan. 2015 June 2016
7-2 " Sept. 2011 Jan. 2015 June 2016
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Maintenance Manual LS8
Issued: December 2009
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0-6
0.3 Table of Contents
SectionContent page
0
General .....................................................................................................0-1
0.1 Manual amendments ................................................................................0-1
0.2 List of effective pages..............................................................................0-3
0.3 Table of Contents.....................................................................................0-6
0.4 Airworthiness limitations.........................................................................0-9
0.4.1 Repairs................................................................................................0-9
0.4.2 Life time of the airframe ....................................................................0-9
0.4.3 Life time of equipment and components ...........................................0-9
0.4.4 Service time, maintenance documents of equipment and components
............................................................................................................0-9
1 Description of systems.............................................................................1-1
1.1 Overview..................................................................................................1-1
1.2 Aileron control system (Fuselage).........................................................1-5
1.3 Air brake system ......................................................................................1-6
1.4 Elevator control system............................................................................1-7
1.5 Wing control systems and wing waterballast (only LS8)........................1-8
1.6 Aileron control system wings (LS8-a, LS8-b, LS8-18)...........................1-9
1.7 Rudder control system ...........................................................................1-10
1.8 Main landing gear ..................................................................................1-11
1.9 Fuselage waterballastsystem (LS8) .......................................................1-12
1.10 Fuselage water ballast system (LS8-a, LS8-18) ....................................1-13
1.11 Fuselage water ballast system (LS8-b) ..................................................1-14
1.12 Wing water ballast system (LS8-a from ser. no. 8066 on, LS8-b, LS8-18)
................................................................................................................1-15
1.13 Wing water ballast system with winglet ventilation (only LS8-a up to ser.
no. 8065) ................................................................................................1-16
1.14 Pressure ports .........................................................................................1-18
1.15 Drain orifices .........................................................................................1-18
1.15.1 Drain orifices (LS8, LS8-18, LS8-b) ...............................................1-18
1.15.2 Drain orifices (LS8-a) ......................................................................1-19
1.16 Primary and secondary structure............................................................1-19
2 Mass and balance .....................................................................................2-1
2.1 Weighing procedure.................................................................................2-1
2.2 Calculation of loading limits....................................................................2-2
2.3 Calculation of maximum mass of non-lifting parts .................................2-6
2.3.1 MNLP LS8.........................................................................................2-6
2.3.2 MNLP LS8-a......................................................................................2-8
2.3.3 MNLP LS8-b and LS8-18................................................................2-10
2.4 Empty mass C.G. range .........................................................................2-12

Maintenance Manual LS8
Issued: February 2011 TN8019
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0-7
SectionContent page
3
Inspections ...............................................................................................3-1
3.1 Ordinary inspections ................................................................................3-1
3.2 Extraordinary inspections after heavy landings.......................................3-5
3.3 Inspection procedure for increase of service time ...................................3-6
3.4 Lubrication schedule................................................................................3-7
4 Working instructions................................................................................4-1
4.1 Removal and installation of control surfaces...........................................4-1
4.1.1 Ailerons ..............................................................................................4-1
4.1.2 Elevator ..............................................................................................4-3
4.1.3 Rudder................................................................................................4-4
4.2 Installation of control surface gap seals...................................................4-5
4.2.1 Gap seals ailerons...............................................................................4-5
4.2.2 Gap seals elevator ..............................................................................4-9
4.2.3 Gap seals rudder..............................................................................4-10
4.3 Seat shell removal and installation ........................................................4-11
4.4 Adjustment of water ballast system.......................................................4-12
4.4.1 Adjustment of water ballast system LS8 .........................................4-12
4.4.2 Adjustment of water ballast system LS8-a, LS8-b, LS8-18 ............4-13
4.4.2.1 Adjustment of water ballast system LS8-a, LS8-b, LS8-18,
instructions for all versions..........................................................4-13
4.4.2.2 Adjustment of water ballast system LS8-a and LS8-18 with slide in
tail fin tank ...................................................................................4-13
4.4.2.3 Adjustment of water ballast system LS8-b and LS8-a and LS8-18
with integral tail tank ...................................................................4-16
4.5 Removal and installation of the slide-in tail tank ..................................4-18
4.6 Removal and installation of wing waterballast bags only LS8 ...............4-19
4.7 Removal and installation of the C.G. hook............................................4-21
4.8 Removal and installation of the nose hook............................................4-23
5 Control surfaces .......................................................................................5-1
5.1 Control surface deflection limits..............................................................5-1
5.2 Control surface mass and mass balance...................................................5-2
5.2.1 Data ....................................................................................................5-2
5.2.2 Instructions.........................................................................................5-4
5.3 Control surfaces free play ........................................................................5-5
5.4 Control surfaces friction ..........................................................................5-5
5.5 Limit values for control surface deflections ............................................5-6
6 List of special tools ..................................................................................6-1

Maintenance Manual LS8
Issued: February 2011 TN8019
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
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0-8
SectionContent page
7
Placards and markings .............................................................................7-1
7.1 LS8 ...........................................................................................................7-1
7.2 LS8-a........................................................................................................7-2
7.3 LS8-b........................................................................................................7-3
7.4 LS8-18......................................................................................................7-4
7.5 LS8, LS8-a, LS8-b, LS8-18 .....................................................................7-5
8 Permanent installation of fixed ballast.....................................................8-1
8.1 Fixed ballast under instrument panel .......................................................8-1
8.2 Fixed Ballast at rear fuselage end............................................................8-2
8.3 Permanent installation of equipment in baggage compartment...............8-3
9 Instruments- and Equipment List (Master Equipment List)....................9-1
9.1 Airspeed Indicator....................................................................................9-1
9.2 Altimeter ..................................................................................................9-1
9.3 Seat Belt Harness (with multiple point buckles) .....................................9-2
9.4 Compass...................................................................................................9-2
9.5 UHF – Transmitter and Receiver.............................................................9-2
9.6 Variometer ...............................................................................................9-3
9.7 Turn and Bank Indicator ..........................................................................9-3
9.8 Thermometer............................................................................................9-3
9.9 Electrical Supply:.....................................................................................9-4
9.10 Equipment, not being part of minimum equipment:................................9-4
10 Materials for repair ................................................................................10-1
11 Repairs ................................................................................................... 11.1
11.1 Composite repairs .................................................................................. 11.1
11.2 Repairs of Metal Fittings ....................................................................... 11.2
11.3 Control cables and connections ............................................................. 11.2
11.4 Longitudinal motion pushrod bearings.................................................. 11.3
12 Appendix................................................................................................ 12.1
12.1 Equipment list ........................................................................................ 12.1
12.2 Annual inspection checklist ................................................................... 12.3

Maintenance Manual LS8
Issued: June 2016 TN 8024
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0-9
0.4 Airworthiness limitations
0.4.1 Repairs
Repair or replace damaged parts prior to next flight. Follow the instructions
of section 11 of this manual for repairs of the airframe.
Note: You will find more detailed instructions in the Repair Manual LS8.
Major repairs must be accomplished by an approved repair station or by an
approved 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 composite sailplanes is 12000
flight hours. Therefore inspections according to section 3.3 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
a) The fabric straps of the safety harness (not the buckles) have to be
exchanged according to the instructions of the respective manufacturer. If
no limitations are given, exchange after 12 years.
b) Other components:
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 72 or Europa G 73 or Europa G 88 Safety Tow Release
latest approved version
And if installed:
Operating Manual for Tow Releases Series: E72 or E75 or E 85 Nose Tow
Release latest approved version
Safety harness: instructions of the manufacturer.
b) Minimum instrumentation: instructions of the manufacturer.

Maintenance Manual LS8
Issued: February 2011 TN8019
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1-1
1Description of systems
1.1 Overview
Wings
LS8 and LS8-a: Wingspan 15 m with removable winglets.
LS8-b and LS8-18: Wingspan variable by exchange of 15m winglets with
18m tips with Winglets.
Aileron Controls
Aileron system activated via pushrods guided in longitudinal motion ball
bearings, connection of system by automatic coupling during rigging.
Dynamic aileron mass balance in wings.
Only LS8: Aileron parted at wing contour brake
LS8-b and LS8-18: Additional ailerons at 18m wingtips.
Elevator Controls
Elevator system activated via pushrods guided in longitudinal motion ball
bearings, automatic coupling of system during rigging. 100% mass
balance in vertical tail fin pushrod.
Rudder Controls
Rudder system activated via steel cables guided in polyamide tubing, no
closed control circuit. mass balance at rudder.
Wheel Brake
Feet operated, activated by bowden cable from rudder pedals.
With TN8019 executed: The wheel brake Bowden cable is connected to the
airbrake drive instead of the rudder pedals.
Air Brakes
Activated via pushrods, guided partly in longitudinal motion ball bearings,
partly in plain bearings. Automatic connection of system during rigging.
Locking mechanism in wings. Upper surface double height air brakes with
spring loaded cover blades. Friction damper in box to prevent oscillations
during extension.
Water Ballast System
LS8:
One double water bag per wing, maximum capacity per wing 75 Liters
<19.8 US gallons, 16.5 Imp. gallons>. Optionally one single water bag ,
maximum capacity per wing 50 Liters <13.2 US gallons, 11 Imp.
gallons>. Double valve or single valve at wing root, one loading and
dumping orifice on under side of wings near root. Automatic
connection during rigging.
In the vertical tail fin either battery receptacle or ballast tank allowing
to compensate C.G. movement due to wing water ballast or mass of
heavy pilots, maximum capacity 5.5 Liters <1.45 US gallons, 1.21 Imp.
gallons>. When the tail fin tank is combined with a battery receptacle,
the maximum capacity is 4.1 Liters <1.08 US gal., 0.9 Imp.gal.>.
(Maximum permissible compensation allowed for in tables)

Maintenance Manual LS8
Issued: December 2009
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1-2
Water Ballast System cont.
LS8-a
Two integral tanks per wing, maximum capacity per wing 95 Litres <25.1
US gallons, 20.9 Imp. gal.>. Two valves at under side of wing for loading
and dumping. Automatic connection during rigging.
Two different ventilation systems: Winglet ventilation or root-rib
ventilation.
Ballast tank in the vertical tail fin allowing to compensate C.G. movement
due to wing water ballast or mass of heavy pilots, capacity between 3.8
Litres <1.0 US gal., 0.84 Imp.gal.> and 12 Litres <3.2 US gal., 2.64 Imp.
gal.>, depending on version (integral or slide-in tank, with or without
battery receptacle).
LS8-b
Two integral tanks per wing, maximum capacity per wing 95 Litres <25.1
US gallons, 20.9 Imp. gal.>. Two valves at under side of wing for loading
and dumping. Automatic connection during rigging.
Ventilation of wing integral tanks by root-rib ventilation.
Ballast tank in the vertical tail fin allowing to compensate C.G. movement
due to wing water ballast or mass of heavy pilots, capacity 7.5 Litres
<1.98 US gal., 1.65 Imp.gal.>.
LS8-18
Two integral tanks per wing, maximum capacity per wing 95 Litres <25.1
US gallons, 20.9 Imp. gal.>. Two valves at under side of wing for loading
and dumping. Automatic connection during rigging.
Ventilation of wing integral tanks by root-rib ventilation.
Ballast tank in the vertical tail fin allowing to compensate C.G. movement
due to wing water ballast or mass of heavy pilots, capacity between 3.8
Litres <1.0 US gal., 0.84 Imp.gal.> and 12 Litres <3.2 US gal., 2.64 Imp.
gal.>, depending on version (integral or slide-in tank, with or without
battery receptacle).

Maintenance Manual LS8
Issued: December 2009
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1-3
Cockpit
Double fiberglass shell. Controls for air brakes, longitudinal trim and trim
position indicator located on left cockpit side, trim locking lever at control
stick. Control for tow cable release on left cockpit frame (operating both
C.G. hook and nose hook), for pedal adjustment on seat, for ventilation on
instrument panel cover, for landing gear and water ballast valves on right
side of cockpit, for canopy opening on both sides. When operating right
canopy lever over full possible travel, the forward canopy mount becomes
unlocked (emergency canopy release).
Canopy
One piece hinged up front with instrument panel cover. In case of an
emergency exit, a spring loaded latch at the rear canopy edge acts as a
temporary hinge for clean separation of the canopy from the fuselage.
Designation of this item in other parts of this manual: LS-latch (Röger
hook) for canopy emergency release
Instrument Panel
Panel lifts together with canopy allowing unobstructed entry and exit.
Depending on version, allows for installation of up to 10 instruments
including radio.
Baggage Compartment
Baggage compartment behind pilot's shoulders is for light and soft
materials only. Permanent installation of batteries or other equipment
possible.
Oxygen System
Receptacle for oxygen bottles provided, size of bottles 3 or 4 Litres,
diameter 100 mm (3.94 in).
Landing Gear
Sprung and retractable, housed in a closed box, right hand operation. Tail
skid including cable deflector or tail wheel optional.
Tail Fin Battery
The tail fin battery may removed to decrease Minimum Cockpit Load. It
must be fitted in the baggage compartment, if there is no other battery
installed.

Maintenance Manual LS8
Issued: December 2009
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1-4
Caution: when working at control systems
To keep humidity out of the pushrods and prevent corrosion, there are no
inspection holes to check rod end depth.
Rod end bearings used may have different thread lengths with identical heads.
Therefore, before adjusting rod end bearings, remaining thread reach must be
checked by disassembly.
Thread diameter Minimum reach x Rod end designation
M6 x 1 (Standart) 17 mm / 0.67 in EM 6 R (used in single
cases only)
M8 x 1,25 (Standart) 17 mm / 0.67 in various versions possible
M10 x 1 (Fine thread) 17 mm / 0.67 in PM 6 long
x

Maintenance Manual LS8
Issued: December 2009
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1-5
1.2 Aileron control system (Fuselage)
No. Designation Drawing No
.
Designation Drawing
1 Forward fuselage aileron
l
3R10-72 7 Rear aileron pushrod 4R10-118
2 Forward aileron pushrod 4R10-73 8 Aileron lever 1R10-178
or 4R10-179 9 Parallelogram pushrod 4R10-49
3 Stick aileron pushrod 4F3-37 10 Aileron lever bearing 4R10-69
4 Control stick 3R3-49 11 Aileron connector 3R10-116
5 Control stick support 1R3-86 12 Automatic connector
bearing
3R10-119
6 Middle aileron pushrod 4R10-74

Maintenance Manual LS8
Issued: February 2011 TN8019
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1-6
1.3 Air brake system
Fuselage Wings
No. Designation Drawing No
.
Designation Drawing
1 Automatic connector bea
r
3R10-119 10 Root rib drive lever 3F4-71
2 Air brake connector 3R6-44 or 3F4-64
3 Air brake drive bracket 3R6-54 11 Root rib bracket 4F3-76
4 Air brake drive 3R6-50 12 Wing pushrod 4F4-63
With TN8019 executed: 13 Locking lever 4F4-53
4 Air brake lever with
wheel brake attachment
14 Inner lever 3F4-51
4A Bowden cable attachment
for wheel brake
9St13
15 Upper blade 3F4-60
5 Intermediate rod 4R10-77 16 Outer lever 3F4-52
6 Sliding member 4R6-47 17 Lower blade 3F4-54
7 Air brake rod 4R6-59 18 Friction brake
8 Air brake lever 3R6-58
9 Lever guide tube 4R6-31

Maintenance Manual LS8
Issued: December 2009
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1-7
1.4 Elevator control system
The mass of the elevator pushrod in the vertical tail fin is adapted to elevator
mass.
See mass value entered in inspection form "Control Surface mass and Moment"
for this serial number
No
.
Designation Drawing
1 Trim locking lever 4R9-24
2 Control stick 3R3-49
3 Control stick
support
1R3-65
4 Trim lever 4R9-95
5 Trim bowden cable
6 Trim rod 4R9-76
7 Trim locking
housing
3R9-74
8 Rear trim spring
9 Vertical tail fin
elevator pushrod
4R3-79
10 Rear horizontal tail
bracket
4R4-6
11 Rear tapered bolts 4R4-4
12 Securing nut 4R4-8
13 Elevator connector
bracket
4R3-62
14 Automatic
connector
3R3-63
15 Elevator lever 4R3-7
16 Elevator lever
bracket
4R3-40
17 Forward trim spring
18 Forward elevator
pushrod
4R3-84
19 Elevator pushrod 2 4R3-85
20 Elevator pushrod 3 4R3-76
21 Rear elevator
pushrod
4R3-69

Maintenance Manual LS8
Issued: March 2016 TN8024
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1-8
1.5 Wing control systems and wing waterballast (only LS8)
Shown: Waterbag LS6-18w: drawing lF-97
(max. 75 Liter per wing)
Fri
ct
i
o
n
b
r
a
k
e

Maintenance Manual LS8
Issued: March 2016 TN8024
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Manual valid with the up-to-date cover page only
1-9
1.6 Aileron control system wings (LS8-a, LS8-b, LS8-18)
No
.
Designation Drawing
1 Root rib bracket 4F3-76
2 Root rib aileron drive 3F3-78
3 Right aileron pushrod 4F3-135
Left aileron pushrod 4F3-139
4 Aileron drive lever 1F3-133
5 Wing aileron drive bracket 4F3-134
6 Aileron drive rod 4F3-137
7 Drive bracket at aileron 4Q1-40
8 Aileron stop 4F32-136

Maintenance Manual LS8
Issued: February 2011 TN8019
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1-10
1.7 Rudder control system
No
.
Designation Drawing
1 Canopy opener bracket 4R8-67
2 Forward pedal guide bracket 3R14-14
3 Upper pedal guide tube 4R14-18
4 Lower pedal guide tube 4R14-19
5 Rudder pedal 1R14-21
6 Pedal support 3R14-16
7 Rear pedal guide bracket 3R14-15
8 Wheel brake cable
8 Not installed with TN8019 executed
9 Rudder cable
10 Pedal adjustment cable 4R14-31
11 Rudder drive bracket 4S1-10