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11) Check the muffler for cracks and ensure mounting is secure.
Check especially the cable which lifts the muffler during engine extension.
Check the moving part at the front end of the muffler for any cracks.
Check the exhaust manifold (already removed) for cracks. Reinstall the
exhaust manifold, therefore remove any remains of the gaskets, install new
gaskets.
Check the length of the cable which lifts the muffler. To accomplish this
extend the engine and press the muffler body in downward direction at its
front end with a force of approx. 50 N (11 lbs.). If the cable is too long or if
the spring in the cable has been permanently stretched, the muffler will
interfere with the exhaust manifold.
Check the spring pressure at the coupling of exhaust manifold to muffler.
To accomplish this, measure the distance between the brackets for the
spring couplings at the muffler pipe and at the movable part of the muffler
in disengaged and in operating position. Extend the powerplant completely
via the manual switch. In this position the distance should be approx. 1 mm
(0.04 in.) smaller than when disengaged. If the difference should be less
than 0.5 mm (0.02 in.) you have to adjust to 1mm using the nut on the
eyebolt. By this procedure you will pull the muffler forwards in its frame.
Note: With new manifold and/or new movable part the difference should be
adjusted to 2 – 3 mm (0.04 – 0.12 in.) to allow breaking in of the parts.
12) Check the spring tension of the bungee which pulls the cable (which lifts
the muffler) back. With engine completely extended pull the bungee
upwards in the centre with a spring balance, hold the front steel cable down
at the muffler lifting cable. With 100 mm deflection the force needed
should be min. 6 N. (1.3 lbs.) If the force is lower or if the bungee is
damaged exchange the bungee.
13) Check the spring tension of the bungee which pulls the muffler down.
retract the engine so far that the muffler disengages and rests on its lower
stop. Install a spring balance to the muffler frame at the point where the
cable running to the bungee is installed. Pull the mufflerframe upwards. A
force of min. 60 N (13 lbs.) should be needed. If the force is lower or if the
bungee is damaged exchange the bungee.
14) Check all engine nuts and bolts with a torque wrench (see section 1.12.9).
15) Check the rubber engine mounts, especially for cracks. Therefore apply
strong pressure to the drive mount in forward, backward and sideways
direction.
Check the rubber buffer which limits the tilt of the engine against the drive
mount due to the engine torque (see diagram 27) according to section
1.12.1. Adjust if necessary.
Issued: October 2012
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only
Maintenance Manual DG-1000M
TN1000/22
3.6
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