Flugzeugbau DG-1001M User manual

MAINTENANCE MANUAL
FOR THE MOTORGLIDER
DG-1001M
TYPE: DG-1000
VARIANT: DG-1000M
TC Data Sheet No.: EASA.A.072
Issued: October 2010
Owner:
Ser.No.:
Registration:
Copyright DG Flugzeugbau GmbH any copy or publishing prohibited
DG Flugzeugbau
Otto Lilienthalweg 2 Telefon [phone]
76646 Bruchsal Telefax [phone]
www.dg-flugzeugbau.de [email protected]
Spare part- and material sales: Tel. [phone]
[e-mail]
DG
FLUGZEUGBAU GMBH

Maintenance Manual DG-1000M
Issued: July 2015 TN1000/27
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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 be found in the sections system description, instructions
for assembly and servicing work, in the partlist in section 8 and especially in the
diagrams of the maintenance manual.
Yours sincerely
DG FLUGZEUGBAU GMBH
Dipl.- Ing. W. Dirks

Maintenance Manual DG-1000M
Issued: July 2015 TN1000/27
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Manual valid with the up-to-date cover page only
0.1
0General
0.1 Manual amendments
No. Page Description Date
1 0.0, 0.1, 0.3 ÷ 0.7, 0.9, 0.12 ÷ 0.14,
1.2, 1.5, 1.8 ÷ 1.12, 1.20, 1.24, 1.31,
1.33, 1.34, 2.1 ÷ 2.4, 2.6, 3.1 ÷ 3.7,
4.6 ÷ 4.8, 4.11, 4.12, 4.19 ÷ 4.24,
4.26, 4.27, 4.29, 4.30, 6.1, 6.4, 7.2,
8.1 ÷ 8.4, diagrams 2, 3, 7, 15, 16,
23, add drawing W59,
10E202 issue C (only with coolant
pump Pierburg)
Manual revision
Alternative for
coolant pump
TN1000/22
October 2012
2 0.1, 0.3, 0.6, 0.11, 0.13, 0.14, 1.3,
1.4, 1.10, 8.2, 8.3, 8.5
Manual revision
TN1000/23
July 2014
3 0.1, 0.3- 0.6, 1.11, 1.28, 3.8, 4.12,
8.2, 8.3, diagram 16
Manual revision
TN1000/27
July 2015

Maintenance Manual DG-1000M
Issued: October 2010
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
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Maintenance Manual DG-1000M
Issued: July 2015 TN1000/27
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Manual valid with the up-to-date cover page only
0.3
0.2 List of effective pages
Section page issued replaced replaced replaced
0 0.0 October 2010
0.1 " See list of amendments
0.2 " See list of amendments
0.3 " See list of amendments
0.4 " See list of amendments
0.5 " See list of amendments
0.6 " See list of amendments
0.7 " See list of amendments
0.8 " October 2012
0.9 " October 2012
0.10 "
0.11 " July 2014
0.12 " October 2012
0.13 " October 2012 July 2014
0.14 " October 2012 July 2014
1.1 October 2010
1.2 " October 2012
1.3 " July 2014
1.4 " July 2014
1.5 " October 2012
1.6 "
1.7 "
1.8 " October 2012
1.9 " October 2012
1.10. " October 2012 July 2014
1.11 " October 2012 July 2015
1.12 " October 2012
1.13 "
1.14 "
1.15 "
1.16 "
1.17 "
1.18 "
1.19 "
1.20 " October 2012
1.21 "
1.22 "
1.23 "

Maintenance Manual DG-1000M
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0.4
List of effective pages (cont.)
Section page issued replaced replaced replaced
1.24 October 2010 October 2012
1.25 "
1.26 "
1.27 "
1.28 " July 2015
1.29 October 2010
1.30 "
1.31 " October 2012
1.32 "
1.33 " October 2012
1.34 " October 2012
1.35 "
2 2.1 October 2010 October 2012
2.2 " October 2012
2.3 " October 2012
2.4 " October 2012
2.5 "
2.6 " October 2012
3 3.1 October 2010 October 2012
3.2 " October 2012
3.3 " October 2012
3.4 " October 2012
3.5 " October 2012
3.6 " October 2012
3.7 " October 2012
3.8 " July 2015

Maintenance Manual DG-1000M
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0.5
List of effective pages (cont.)
Section page issued replaced replaced replaced
4 4.1 October 2010
4.2 "
4.3 "
4.4 "
4.5 "
4.6 " October 2012
4.7 " October 2012
4.8 " October 2012
4.9 "
4.10 "
4.11 " October 2012
4.12 " October 2012 July 2015
4.13 "
4.14 "
4.15 "
4.16 "
4.17 "
4.18 "
4.19 " October 2012
4.20 " October 2012
4.21 " October 2012
4.22 " October 2012
4.23 " October 2012
4.24 " October 2012
4.25 "
4.26 " October 2012
4.27 " October 2012
4.28 "
4.29 " October 2012
4.30 " October 2012
4.31 "
4.32 "
4.33 "
4.34 "
5 5.1 October 2010
5.2 "
6 6.1 October 010 October 2012
6.2 " October 2012
6.3 "
6.4 " October 2012

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0.6
List of effective pages (cont.)
Section page issued replaced replaced replaced
7 7.1 October 2010
7.2 October 2012
8 8.1 October 2010 October 2012
8.2 " October 2012 July 2014 July 2015
8.3 " October 2012 July 2014 July 2015
8.4 " October 2012
8.5 July 2014
9 9.1 October 2010
9.2 "
9.3 "
9.4 "
9.5 "
9.6 "
Diagram issued replaced replaced replaced replaced
1 October 10
2 October 10 October 2012
3 June 05 October 2012
4 Nov. 01
5 October 10
6 October 10
7 October 10 October 2012
8 October 10
9 October 10
10 October 10
11 October 10
12 October 10
13 October 10
14 October 10
15 October 10 October 2012
16 October 10 October 2012 July 2015
17 October 10
18 October 10
19 October 10
20 October 10
21 October 10
22 October 10
23 October 10 October 2012
24 October 10
25 October 10
26 October 10
27 October 10

Maintenance Manual DG-1000M
Issued: October 2012 TN1000/22
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0.7
List of effective pages (cont.)
Enclosures issued replaced replaced
5EP31 Installation plan Dräger oxygen
system
5.02.90
10E4 Wiring plan electrically operated
main landing gear
28.09.10
10E202 Wiring plan DINA1 (in aircraft log) 29.07.10 28.09.12
issue C
With coolant
pump Pierburg
5V18 Tool for airbrake adjustment 14.10.94
W51 Hook spanner for upper drive belt
pulley bearings
20.11.96
W59 Test adapter 18.06.02
W66 Tool to check drive belt tension 17.09.10
Z181 Installation of aerial for transponder
in vertical fin DG-1000
18.04.08
Z193 406 MHZ ELT antenna BD3
installation 2-seaters
4.11.09
SI
67/07
Service Info Ballast box in the fin /
foam rubber rings
5.11.2007

Maintenance Manual DG-1000M
Issued: October 2010
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0.8
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..................................................................................... 0.8
0.4 Airworthiness limitations....................................................................... 0.13
0.4.1 Repairs.............................................................................................. 0.13
0.4.2 Life time of the airframe .................................................................. 0.13
0.4.3 Life time of equipment and components ......................................... 0.13
0.4.4 Service time, maintenance documents of equipment and components
.......................................................................................................... 0.14
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 control ......................................................................................... 1.6
1.5 Airbrake control, wheelbrake .................................................................. 1.8
1.6 Undercarriage........................................................................................... 1.9
1.7 Tow hooks.............................................................................................. 1.12
1.8 Water ballast system .............................................................................. 1.13
1.9 Ballast box in the fin .............................................................................. 1.14
1.10 Massbalance and weights of control surfaces........................................ 1.15
1.11 Fore and aft play of the wings ............................................................... 1.16
1.12 Power Plant ............................................................................................ 1.17
1.12.1 Arrangement..................................................................................... 1.17
1.12.2 Engine type, coolant......................................................................... 1.17
1.12.3 Exhaust Muffler ............................................................................... 1.17
1.12.4 Propeller ........................................................................................... 1.17
1.12.5 Reduction gear ................................................................................. 1.18
1.12.6 Starter motor .................................................................................... 1.18
1.12.7 Fuel injection and ignition system ................................................... 1.18
1.12.8 Throttle control ................................................................................ 1.18
1.12.9 Tightening torques and locking ....................................................... 1.19
1.12.10 Fire warning device.......................................................................... 1.19
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.............................................................................. 1.20
1.13.5 Adjustment of the powerplant positions .......................................... 1.21

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Sectioncontent page
1.14
Fuel system ............................................................................................ 1.22
1.14.1 Layout .............................................................................................. 1.22
1.14.2 Tank.................................................................................................. 1.22
1.14.3 Fuel pumps and filters...................................................................... 1.22
1.14.4 Fuel pressure regulator..................................................................... 1.23
1.14.5 Fuel pressure switch......................................................................... 1.23
1.14.6 Fuel injection.................................................................................... 1.23
1.14.7 Fuel cock .......................................................................................... 1.23
1.14.8 Fuel quantity indication ................................................................... 1.23
1.15 Electrical system .................................................................................... 1.24
1.15.1 Layout .............................................................................................. 1.24
1.15.2 Batteries ........................................................................................... 1.24
1.15.3 Control unit ...................................................................................... 1.25
1.15.4 Engine control unit and sensors ....................................................... 1.26
1.15.5 Generator - Regulator ...................................................................... 1.27
1.15.6 Master Switch .................................................................................. 1.27
1.15.7 Engine elapsed - time indicator........................................................ 1.27
1.15.8 Electric fuel pumps and fuel pressure switch .................................. 1.27
1.15.9 12 V Socket...................................................................................... 1.27
1.15.10 Power plant extension/retraction mechanism .................................. 1.28
1.15.11 Manual extension-retraction switch................................................. 1.28
1.15.12 Starter Press Button.......................................................................... 1.28
1.15.13 Wiring .............................................................................................. 1.29
1.15.14 Circuit breakers and fuses................................................................ 1.30
1.15.15 Position switches for the powerplant ............................................... 1.31
1.15.16 Proximity switch .............................................................................. 1.31
1.15.17 External power supply socket (Option) ........................................... 1.31
1.15.18 Refuelling pump system .................................................................. 1.31
1.15.19 Connector plugs between fuselage and engine................................ 1.32
1.15.20 DEI-NT (Digital Engine Indicator).................................................. 1.32
1.15.21 Coolant pump……………………………………………………...1.33
1.15.22
Electrical system of the electrically operated main landing gear .... 1.34
1.16 Pitot and static system............................................................................ 1.35
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

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0.10
Sectioncontent page
3
Maintenance............................................................................................. 3.1
3.1 General maintenance................................................................................ 3.1
3.2 Maintenance of the airframe .................................................................... 3.2
3.3 Greasing and oiling .................................................................................. 3.2
3.4 Damage of the airframe ........................................................................... 3.3
3.5 Hydraulic wheel brake ............................................................................. 3.3
3.6 Servicing the Engine................................................................................ 3.4
3.6.1 25 hour inspection.............................................................................. 3.4
3.6.2 After every 100 engine hours............................................................. 3.8
3.6.3 After every 400 engine hours............................................................. 3.8
3.6.4 After 6 years....................................................................................... 3.8
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
4.5 Removal and installation of the undercarriage (main wheel).................. 4.6
4.6 Filling and bleeding the hydraulic disc brake........................................ 4.11
4.7 Control surface seals and turbulators..................................................... 4.13
4.7.1 Ailerons ............................................................................................ 4.13
4.7.2 Wing lower surface .......................................................................... 4.15
4.7.3 Horizontal tailplane.......................................................................... 4.15
4.7.4 Vertical tailplane.............................................................................. 4.16
4.8 Working instructions for heat-shrink tubing.......................................... 4.17
4.9 Securing with Loctite............................................................................. 4.17
4.10 Working at the powerplant .................................................................... 4.18
4.10.1 Removal and assembly of the engine doors..................................... 4.18
4.10.2 Mounting and tensioning of the drive belts ..................................... 4.19
4.10.3 Replacing the bearings of the upper drive belt pulley ..................... 4.20
4.10.4 Replacement of the engine retaining cable...................................... 4.22
4.10.5 Filling and bleeding the cooling system .......................................... 4.23
4.10.6 Securing the propeller bolts and the bolts of the rear engine mount4.25
4.10.7 Installation and removal of the extension/retraction unit ................ 4.26
4.10.8 Removal and installation of the tension gas-strut............................ 4.27
4.10.9 Removal and reinstallation of the powerplant ................................. 4.29
4.10.10 Removal and reinstallation of the engine (from the drive mount) .. 4.30
4.10.11 Removal and reinstallation of the lower drive belt pulley with starter
ring gear ........................................................................................... 4.31
4.10.12 Checking the ignition unit and the generator................................... 4.32

Maintenance Manual DG-1000M
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0.11
Sectioncontent page
4.11
DEI-NT settings ..................................................................................... 4.33
4.11.1 Calibration of the fuel display in the DEI-NT ................................. 4.33
4.11.2 Further DEI-NT settings .................................................................. 4.33
4.11.3 Download of flight log and service data.......................................... 4.34
5 Weight and balance.................................................................................. 5.1
6 Instrumentation and accessories list ........................................................ 6.1
6.1 Air speed indicator................................................................................... 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 ............................................................................................... 6.3
6.7 Turn and bank indicator........................................................................... 6.3
6.8 Outside air temperature gauge ................................................................. 6.3
6.9 Engine instrumentation ............................................................................ 6.3
6.10 Instruments which are not part of the minimum equipment:................... 6.4
6.10.1 Transponders:..................................................................................... 6.4
6.10.2 ELT: ................................................................................................... 6.4
6.10.3 Other instruments and equipment (eg. variometers, gliding computers
or flight data recorders):..................................................................... 6.4
7 List of special tools etc. ........................................................................... 7.1
8 Partlist ...................................................................................................... 8.1
8.1 Parts for the powerplant ........................................................................... 8.1
8.1.1 Parts necessary for the 25 hours inspection....................................... 8.1
8.1.2 Spare parts.......................................................................................... 8.1
8.2 Control surface sealings and turbulators.................................................. 8.4
8.3 Parts for landing gear ............................................................................... 8.4
8.4 Other parts ……………………………………………………………..8.5
9
Enclosures ................................................................................................ 9.1
9.1 Equipment list .......................................................................................... 9.1
9.2 Checklist for checks and maintenance work ........................................... 9.2
9.3 Instruction for downloading log book and service data from the DEI-NT
.................................................................................................................. 9.3

Maintenance Manual DG-1000M
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0.12
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
7 Main landing gear, hydraulic wheel brake, installation in the LG box,
page 1
8 Main landing gear, hydraulic wheel brake, installation in the LG box,
page 2
9 Main landing gear control
10 Tail wheel
11 Systems for static and total pressure
12 Placards
13 Powerplant
14 Cooling system
15 Propeller stopper
16 Fuel system
17 Engine door control
18 Powerplant retaining cable
19 Assembly upper drive belt pulley
20 Engine mount front
21 Engine mount rear
22 Main powerplant bearings
23 Exhaust system
24 Placards electrically operated main landing gear
25 Extension/retraction mechanism connection to powerplant
26 Extension/retraction mechanism connection to fuselage
27 Engine - tilt limit stop
5EP31 Installation plan Dräger oxygen system
10E4 Wiring plan electrically operated main landing gear
10E202 Wiring plan DINA1 (in aircraft log)
5V18 Tool for airbrake adjustment
W51 Hook spanner for upper drive belt pulley bearings
W59 Test adapter (for coolant pump check)
W66 Tool to check drive belt tension
Z181 Installation of aerial for transponder in vertical fin DG-1000
Z193 406 MHZ ELT antenna BD3 installation 2-seaters
SI 67/07 Service Info Ballast box in the fin, foam rings

Maintenance Manual DG-1000M
Issued: July 2014 TN1000/23
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0.13
0.4 Airworthiness limitations
0.4.1 Repairs
Repair damaged airframe parts prior to next flight. Follow the instructions of
the DG-1000 repair manual. Repairs outside the scope of the DG-1000
repair manual and major repairs must be accomplished at 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 the variant DG-1000M 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. 39001028
2. The bearings in the upper drive belt pulley, part no. 59332050 and
59320320
b) The gasket for the drainer valve has to be exchanged after 6 years, part no.
60504402.
c) The
full tank sensor has to be exchanged after 6 years, part no. 45001605.
d) The coolant hoses , part no. 39001029 and the coolant (type see section
2.12.2) have to be exchanged after 6 years.
e) All flexible fuel lines have to be exchanged after 6 years (part no. see section
8.1.2.3).
f) The drive belts have to be exchanged after 100 engine hours, part
no.60510831).
g) The spark plugs have to be exchanged after 100 engine hours, part
no.40050360.
h) 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 6.3.
i) 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.

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0.14
j) The brake fluid of the wheel brake has to be exchanged after 4 years (types
see section1.6.2).
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.
0.4.4 Service time, maintenance documents of equipment and components
Follow the instructions of the respective manufacturer.
a) Tow releases:
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 6.3.
c) Minimum instrumentation: instructions of the manufacturer, approved
instruments see sections 6.1, 6.2 and 6.4.
d) Engine: Manual for the engine SOLO Type 2625 02 I, latest approved
version.
e) Propeller: Operation- and Maintenance manual for fixed pitch propeller
in Glass or Carbon reinforced Plastic type BM, latest approved version.
0.4.5 Power plant trouble shooting
Please find a checklist in AFM section 8.8.
Only for USA
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.

Maintenance Manual DG-1000M
Issued: October 2010
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1.1
1System 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: approx. 125/min
Aircraft should rest on main wheel and tailwheel during frequency
measurements

Maintenance Manual DG-1000M
Issued: October 2010
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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° 77 up to 79 mm (3.03 up to 3.11 in.)
down: 21° 61 up to 63 mm (2.40 up to 2.48 in.)
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.
up
down

Maintenance Manual DG-1000M
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1.3
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.
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-1000M 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-1000M
Issued: July 2014 TN1000/23
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1.4
1.2.6 Pilot force reducing rubber-cord
The rubber cord (part No. 30091131 dia. 6 mm white) 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.