Glaser-Dirks DG-300 User manual

Maintenance Manual DG-300
Issued: December 2009 0.0
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
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 and especially in the diagrams of the maintenance
manual.
Yours sincerely
GLASER-DIRKS FLUGZEUGBAU GMBH
Dipl, Ing. W. Dirks

Maintenance Manual DG-300
Issued: Issued: August 2020 TN DG-SS-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
Combination of the initial
Maintenance Manuals of the
Variants DG-300, DG-300
ELAN, DG-300 ELAN
ACRO, DG-300 Club ELAN
and DG-300 Club ELAN
ACRO, new standardized
format
December 2009
0.2
0.7, 1.10, 1.12, 2.1,
2.4, 3.2, 4.1, 4.2,
5.1, 5.2, 6.1, 6.2
Miscellaneous changes to the
contents of the latest
amendments of the initial
maintenance manuals
December 2009
1
0.1, 0.3 – 0.8, 1.4,
2.1, 6.3, 8.8 – 8.12,
9.9 – 9.12
TN DG-SS-05
Manual revision
Inclusion of TN359/4 and
TN359/24
August 2020

Maintenance Manual DG-300
Issued: December 2009 0.2
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
Page intentionally left blank

Maintenance Manual DG-300
Issued: August 2020 TN DG-SS-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
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Maintenance Manual DG-300
Issued: August 2020 TN DG-SS-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
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4.1
December 09
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Diagrams
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Enclosures
9
9.1
31.01.84
9.2
19.08.87
9.3
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Dec. 84
9.8
Oct. 87
9.9
August 20
-9.12

Maintenance Manual DG-300
Issued: August 2020 TN DG-SS-05 0.5
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0.3 Table of contents
Section content page
0 General .......................................................................................................0.1
0.1 Amendments...........................................................................................0.1
0.2 List of effective pages............................................................................0.3
0.3 Table of contents....................................................................................0.5
0.4 Airworthiness limitations.......................................................................0.8
0.4.1 Repairs............................................................................................0.8
0.4.2 Life time of the airframe................................................................0.8
0.4.3 Life time of equipment and components........................................0.8
0.4.4 Service time, maintenance documents of equipment and
components....................................................................................0.8
1 System description and adjustment data....................................................1.1
1.1 Wing and tailplane setting data..............................................................1.1
1.2 Elevator deflections and adjustment......................................................1.2
1.3 Rudder....................................................................................................1.4
1.4 Aileron control .......................................................................................1.5
1.5 Airbrake control circuit, wheelbrake .....................................................1.6
1.6 Landing gear...........................................................................................1.7
1.7 Tow hooks..............................................................................................1.9
1.8 Water ballast system ..............................................................................1.9
1.9 Massbalance and weights of control surfaces......................................1.11
1.10 Fore and aft play of the wings..............................................................1.12
2 Inspections..................................................................................................2.1
2.1 Daily inspection......................................................................................2.1
2.2 Regularly inspections.............................................................................2.1
2.3 Inspection after a heavy landing ............................................................2.2
2.4 Inspection procedure for increase of service time .................................2.4
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

Maintenance Manual DG-300
Issued: August 2020 TN DG-SS-05 0.6
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
Section content page
4 Detailed instructions for assembly and servicing work.............................4.1
4.1 Replacement of the water ballast bags...................................................4.1
4.2 Replacement of control circuit cables....................................................4.1
4.3 Adjustment work on the control circuit.................................................4.2
4.4 Removal and installation of the retractable landing gear......................4.2
4.5 Removal and installation of the fix landing gear...................................4.3
4.6 Removal and reinstallation of the ailerons.............................................4.4
4.7 Increasing the aileron massbalancing ....................................................4.7
4.8 Fixing excessive free play of the canopy...............................................4.8
5 Centre of Gravity measurements-weighing ...............................................5.1
6 Instrument- und equipment 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 (as min. equipment only necessary for cloud flying).............6.2
6.5 VHF transceiver .....................................................................................6.2
6.6 Variometer (as min. equipment only necessary for cloud flying) .........6.2
6.7 Turn and bank indicator (as min. equipment only necessary for cloud
flying)......................................................................................................6.2
6.8 Outside air temperature gauge ...............................................................6.3
6.9 Beschleunigungsmesser .........................................................................6.3
6.10 Instruments which are not part of the minimum equipment:.................6.3
7 Liste der Spezialwerkzeuge........................................................................7.1
8 Diagrams ....................................................................................................8.1
Diagram 1 Elevator control circuit, adjustment 8.1
Diagram 2 Rudder control circuit, retractable landing gear ..............................8.2
Diagram 3 Fix landing gear................................................................................8.3
Diagram 4 Aileron and spoilers control circuits, wheel brake...........................8.4
Diagram 5 Tow hook, water ballast release systems DG-300, DG-300 ELAN,
DG-300 ELAN ACRO.......................................................................................8.5
Diagram 6 Tow hook, water ballast release systems DG-300 Club ELAN, DG-
300 Club ELAN ACRO.............................................................................8.6
Diagram 7 Empty weight centre of gravity range..............................................8.7
Diagram 8 Placards DG-300 & DG-300 ELAN................................................8.8
Diagram 9 Placards DG-300 ELAN ACRO ......................................................8.9
Diagram 10 Placards DG-300 Club ELAN......................................................8.10
Diagram 11 Placards DG-300 Club ELAN ACRO .........................................8.11
Diagram 12 Placards if TN359/24 instruction A is applicable........................8.11

Maintenance Manual DG-300
Issued: August 2020 TN DG-SS-05 0.7
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
9. Enclosures
Installation sketch EFK......................................................................................9.1
Installation sketch 3 ED .....................................................................................9.2
instruction: convertion from fix to retractable landing gear..............................9.3
instruction: convertion from retractable to fix landing gear..............................9.5
drawing FW 25: front landing gear lock............................................................9.7
Installation sketch EFWK ..................................................................................9.8
L´Hotellier maintenance instructions IMA 10.01 9.9

Maintenance Manual DG-300
Issued: August 2020 TN DG-SS-05 0.8
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
0.4 Airworthiness limitations
0.4.1 Repairs
Repair or replace damaged parts prior to next flight. Follow the instructions
of the DG-300 repair manual for repairs of the airframe. Repairs outside the
scope of the DG-300 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 Variants DG-300, DG-300
ELAN, DG-300 ELAN ACRO, DG-300 Club ELAN and DG-300 Club
ELAN ACRO 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
a) 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.
b) other components:
All other components such as 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 release: Operating manual latest approved version for
Only DG-300 ser.No. 1-6: Safety release “SH72” and S72”
all other ser.No.s:
release mechanism safety release G 72 and G 73
or tow release Series: Europa G 88 Safety Tow Release
and if installed,
nose release E 72 and E 75
or tow releases Series: E 85 Nose Tow Release
b) safety harness: instructions of the manufacturer.
c) minimum instrumentation: instructions of the manufacturer.

Maintenance Manual DG-300
Issued: December 2009 1.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
1System description and adjustment data
1.1 Wing and tailplane setting data
Wing
Sweep Back (leading edge): 0 at wing tip (tolerance ± 5 mm, ± 0,2
inch)
Dihederal (leading edge line): 3° = 377 mm at the tip (14,84 inch)
Angles of incidence
Wing oscillation frequency: 136 up to 140 /min.
Aircraft should rest on both wheels during frequency measurements.
fuselage centre line (corresponding to
boom slope 100 : 3.67)
profile chords