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
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issued
replaced
replaced
replaced
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December 09
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Diagrams
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8.6
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8.7
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8.8
"
August 20
8.9
"
August 20
8.10
"
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8.11
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8.12
August 20
Enclosures
9
9.1
31.01.84
9.2
19.08.87
9.3
December 09
9.4
"
9.5
"
9.6
"
9.7
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
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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
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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
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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

Maintenance Manual DG-300
Issued: December 2009 1.2
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
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measuring stick (one end on the floor)
parallel to stabilizer surface!
63 ± 1 mm
2,48 ± 0,04 inch
36 ± 1 mm
1,42 ± 0,04 inch
elevator
Lock
nut
adjustment
screw
1.2 Elevator deflections and adjustment
1.2.1 Control circuit
see diagram 1
1.2.2 Elevator deflections and tollerance:
Up 63 ± 1 mm 2,48 ± 0,04 inch
Down 36 ± 1 mm 1,42 ± 0,04 inch
measured 150 mm (5,9 inch) from hinge axis.
The adjustment is made at the base of the control column. To measure the
displacement lay a straight edge over the elevator and trailing surface of the
stabilizer (which is flat in this area). The straight edge must lie parallel to
the stabilizer surface. Holding a measuring stick with one end on the floor
mark the 0 point on the stick. Then measure the up and down displacements
from this zero point.
1.2.3 Elevator stops:
The elevator stops are located at the base of the controle 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 3 mm (0,12 inch).
Within the automatic elevator connection,
there should be no free play, noticeable
when the elevator is moved at its trailing
edge. And free play can be reduced by
screwing in the adjustment screw on the
automatic connector funnel.

Maintenance Manual DG-300
Issued: December 2009 1.3
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1.2.5 Trim:
The automatic trim mechanism should be
adjusted so that with full forward (nose down)
trim, the control column is from 1 to 1,5 cm (0,4
– 0,6 inch) away from its maximum forward
position. The tensioning of the trim mechanism
springs is to adjust as shown on the sketch. (360 mm; 14,2 inch)
1.2.6 Repair of the automatic trim mechanism bowden cable:
In the event of a replacement bowden cable being installed, it should be
ensured that the cable passes between the two parallel arms of the control
column mechanism as shown in the sketch.
If the cable passes outside the mechanism
control column movement could be
blocked.

Maintenance Manual DG-300
Issued: August 2020 TM DG-SS-05 1.4
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
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1.3 Rudder
1.3.1 Rudder Control circuit
see diagram 2
1.3.2 Rudder deflections and tollerance:
± 215 ± 5 mm (± 30°) (8,46 ± 0,2 inch)
measured at 414 mm (16,3 inch) from the hinge axis.
1.3.3 Rudder stops
The rudder Stopps are located at the lower hinge point and can be adjusted
with a 10 mm open end spanner.
1.3.4 Axial free play
The maximum allowable free play at the upper hinge point is 0,5 mm (0,02
inch).
maximal
0,5 mm
1.3.5 Sealing the rudder
The rudder is sealed on both sides with a V sealing band (3M Scotch
Flexodicht Band 2743 white) which is attached within the fin spar space.
This seal is not to be removed. If damaged it should be replaced and
sprayed with Teflon.
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.

Maintenance Manual DG-300
Issued: December 2009 1.5
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1.4 Aileron control
1.4.1 Control circuit
see diagram 3
1.4.2 Aileron deflections and tolerances
up
62 ± 3 mm (2,44 ± 0,12 in.)
down
31 ± 3 mm (1,22 ± 0,12 in.)
measured at 120 mm (4.72 in.) from hinge axis (at inboard end)
1.4.3 Aileron stops
The aileron stops are located behind the removable left-hand side panel.
The stops can be adjusted with two 4 mm (5/32 in.) diameter rods or drills.
1.4.4 Free play
The max. free play measured at the trailing edge of the ailerons measured at
120 mm (4.72 in.) from hinge axis should not exceed 2 mm (0.08 in.) The
control stick and should be in neutral position. For the measurement fix the
aileron of the opposite wing.
With larger free play the hinge axis (Part No. 2F7/3) should be replaced.
With both ailerons fixed, a maximum free play of 3 mm (0.12 in.) at the top
of the control stick is allowed.

Maintenance Manual DG-300
Issued: December 2009 1.6
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
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1.5 Airbrake control circuit, wheelbrake
1.5.1 Control circuit
see diagram 3
The wheelbrake cable is connected to the airbrake torsion shaft (part 3 St
3).
1.5.2 Adjustment
a) Airbrake overcentre locking force
Adjust the airbrake rod in the airbrake box so that both airbrakes retract
evenly and that the overcentre locking force on the airbrake operating
handle is between 15 - 20 daN (33 – 44 lbs). Adjustment can be done with a
13 mm open ended spanner.
b) Airbrake extension height
The height the airbrakes extend depends on the wheelbrake adjustment.
c) Wheel braking force
With insufficient braking effect, the wheelbrake can be adjusted by a screw
on the end of the bowden cable housing, located on the forward landing
gear fork above the brake actuating lever.
The wheelbrake should not be adjusted any further than that which would
allow a minimum airbrake extension above the top of the wing of 38 mm
(1,5 in.).
1.5.3 Airbrake stops
The rear airbrake control circuit stop at the cockpit bulkhead is not
adjustable. The forward control stop is in the wings and not adjustable.
1.5.4 Free Play
Free play in the airbrake control system is of no effect. The airbrakes itself
at their hinges should not have so much free play that they hit the wing
surface instead of entering into their boxes during retraction under airloads.

Maintenance Manual DG-300
Issued: December 2009 1.7
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
1.6 Landing gear
A retractable landing gear (for all Models)
1.6.1 Landing gear Control circuit
see dDiagram 2
1.6.2 Adjustment
a) Should the landing gear not retract fully, an adjustment can be made by
screwing out the universal pushrod joint on pushrod No. FW 9a/3 with a 10
mm open end spanner.
b) The lock in extended position is by means of the gas strut in the landing
gear box and additionally by a rubber buffer in the cockpit The clearance
between the locking latch at the handle and the front end of the rubber
buffer should be 0,5 to max. 1 mm (.02 to max. .04 in.) with the spring
suspension of the landing gear fully extended.
Adjustment can be made at the mounting of the rubber buffer.
Without TN 359/22: The friction of the handle in sense of rotation should
be adjusted so, that you can just rotate the handle.
With TN 359/22: A torsion spring is installed to keep the handle in the
locked position.
1.6.3 Free Play
Free play between lever FW 8b and the pivot bar FW 21/3 is not allowed. If
there is any free play, then the two securing bolts M 6 x 40 should be
tightened with a 10 mm open end spanner. If there is still some free play,
the bolts should be removed and the holes drilled out and reamed to
diameter 8 H 7. M8 x 40 LN 9037 bolts should then be installed.
1.6.4 Main wheel tyre pressure:
retractable landing gear 3,5 bar (49 psi)
fix landing gear 3,0 bar (42 psi)
1.6.5 Tail wheel tyre pressure:
2 bar (28 psi)

Maintenance Manual DG-300
Issued: December 2009 1.8
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
B Fix landing gear
(only DG-300 Club ELAN and DG-300 Club ELAN ACRO))
1.6.6 System
see diagram 3
1.6.7 Convertion to retractable landing gear
The convertion is possible, as the mounting bushes in the landing gear box
are the same and the stands for the control circuit are already installed.
Further details see enclosure to this manual.

Maintenance Manual DG-300
Issued: December 2009 1.9
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
1.7 Tow hooks
1.7.1 Tow release circuit
see diagram 5 and installation sketch EFK in case an optional hook for
aerotow is installed.
1.7.2 Adjustment
There should be 5 + 2 mm (0.2 in. + 0.08 in.)
space between the tow release knob and the
nylon cable guide.
1.7.3 Check
The ring muzzle of the C.G. hook should not be bent or ground down and
move easily. If the muzzle is damaged, the tow release has to be exchanged
and repaired by the manufacturer (Tost).
1.7.4 Removing the tow hooks
The tow hooks are to be removed in an upward direction (use a piece of
hard wood and a hammer). Be careful not to break loose the seat shell with
the C.G. tow hook.
1.7.5 Operating and maintenance instructions
For further information refer to the operating and maintenance instructions
for the release mechanism see page 3 of this maintenance manual.
1.8 Water ballast system
DG-300, DG-300 ELAN and DG-300 ELAN ACRO see diagram 5
DG-300 Club ELAN and DG-300 Club ELAN ACRO see diagram 6
a) Wing tanks
1.8.1 Water ballast release circuit
see diagram 5
1.8.2 Adjustment
For the dump valve in the closed position, there should be 1 mm (.039 in.)
space between the 8 mm (.315 in.) diameter PVC rod from the dump valve,
and the lever plate on the fuselage. Adjust at the adjustment screw located
at the fuselage wall. If this is insufficient, the 8 mm PVC rod can be
shortened. If a valve still leaks, then the rubber gasket and the associated
spring at the end of the 8mm PVC rod should be loosened, pressed further
in and secured again. If this is not successful, the valve ball seat should be
greased. (see sect. 4.1).
5 ±2

Maintenance Manual DG-300
Issued: December 2009 1.10
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
1.8.3 Servicing
see sect. 4.1
b) Fin tank DG-300, DG-300 ELAN und DG-300 ELAN ACRO
1.8.4 Fin tank adjustment
The release cable must be adjusted so, that the wing tank handles only can be
opened, when the fin tank has been opened fully.
1.8.5 Fin tank inspection
a) According to sect. 2.2.1 a special inspection is to be carried out on the fin
ballast tank system. Therefor the tailwheel is to be dissasembled and the
cover plate in the tailwheel box to be unscrewed.
Check the control cable and the lever of the valve carefully for wear.
The control cable has to be checked at the operating lever in the cockpit
too. If the cable or the lever is worn, it is prohibited to use the fin tank any
more. Please contact DG Flugzeugbau for a detailed repair instruction.
The dump time of the full fin tank is to measure. 120 sec. should not be
exceeded.
Check the calibration of the outside airtemperature gauge.
b) in addition for fin tank with measuring stick
If the dump time increases 120 seconds, the tank may be flushed through
the dump hole with the valve in open position and the fuselage in inverted
position for some minutes. Therefor the strainer at the filling hole is to be
taken out.
Check the water quantity indicator measuring stick for frictionless
movement and proper calibration.
c) Outside air temperature gauge: Check for correct indication.

Maintenance Manual DG-300
Issued: December 2009 1.11
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
1.9 Massbalance and weights of control surfaces
After repairs or repainting the control surfacesweights and moments should
not exceed the following limits:
Control surface
Weight
Moment
Spring balance
reading when attached
to the points described
kg
(lbs)
kg · cm
(lbs · inch)
kg
(lbs)
max.
min.
max.
min.
max.
min.
Rudder (with
massbal.)
4
(8,82)
2,5
(5,51)
6
(5,21)
4
(3,47)
0,3
(0,661)
0,2
(0,441)
Elevator (pushrod
disconnected)
2,2
(4,85)
1,6
(3,53)
8,7
(7,55)
6,7
(5,82)
0,58
(1,279)
0,447
(0,985)
Aileron
(with massbal.)
5,7
(12,57)
3
(6,62)
9,9
(8,55)
8
(6,94)
0,66
(1,45)
0,533
(1,175)
Caution:
Before any changes to the massbalance weights are made, contact the Glaser-
Dirks factory. For changes at the ailerons see also sect. 4.5.
Method for determining control surface moments
Rudder:
Disconnect rudder cables, lay the fuselage on its side so that the fin is horizontal.
Attach (by tape) a spring balance to the lower end of the rudder 200 mm (7.87
inch) behind the hinge axis.
Elevator:
Hang the elevator friction free on its hinge points (pushrod disconnected) and
attach the spring balance 150 mm (5.9 inch) behind the hinge axis.
Aileron:
Hang the aileron friction free on its hinge points(pushrod disconnected) and
attach the spring balance 150 mm (5.9 inch) (countour brake) behind the hinge
axis.