Page 1 DG Flugzeugbau GmbH Otto-Lilienthal-Weg 2 / Am Flugplatz  D-76646 Bruchsal  Germany Postbox 1480, D-76604 Bruchsal  Deutschland Tel. 07251/3020-100  Telefax 07251/3020-200  eMail: dg@dg-flugzeugbau.de Spare part and material sales: Tel. 07251/3020-270  lager@dg-flugzeugbau.de http://www.dg-flugzeugbau.de M A I N T E N A N C E M A N U A L...
Page 2: Sept
Maintenance Manual DG-808C 0 General 0.1 Manual amendments No. Page Description Date 0.3, 0.6, 0.10, 1.11, 8.2, ÄM 800-17-07 April 2007 diagrams 5a, 11d, 8EP210 Fin tank valve and operating handle, Refuelling pump 0.3, 0.4, 0.6, 0.7, 0.10, 0.12, TN800/34 September 1.28, 1.29, 2.7, 3.3, 3.5, 3.11, Manual revision...
Page 3: June
Maintenance Manual DG-808C This page was intentionally left blank. Issued: June 2005...
Page 4 Maintenance Manual DG-808C 0.2 List of effective pages Section page issued replaced/ replaced/ replaced/ June 2005 July 2017 see manual amendments " " " " " June 2005 Sept. 2007 May 2012 " May 2012 " May 2012 0.10 " Sept.
Page 5 Maintenance Manual DG-808C List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ 1.26 June 2005 1.27 " May 2012 1.28 " Sept. 2007 1.29 " Sept. 2007 May 2012 1.30 May 2012 June 2005 May 2012 July 2017 "...
Page 6 Maintenance Manual DG-808C List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ 4.17 June 2005 4.18 " May 2012 4.19 " May 2012 4.20 " May 2012 4.21 " May 2012 4.22 " May 2012 4.23 " May 2012 4.24 "...
Page 7: Table Of Contents
Maintenance Manual DG-808C 0.2 List of effective pages (continued) diagram issued replaced/ replaced/ replaced/ June 2005 May 2012 June 2005 May 2012 Nov. 2004 May 2012 July 2017 Nov. 1993 May 2012 Nov. 2004 May 2012 valid up to ser. No. 8-372 April 07 May 2012 valid from ser.
Page 8 Maintenance Manual DG-808C 0.3 List of content Section content page 0 General 0.1 Manual amendments ................0.1 0.2 List of effective pages ................0.3 0.3 List of content ..................0.7 0.4 Airworthiness limitations ..............0.11 0.4.1 Repairs ................... 0.11 0.4.2 Life time of the airframe ............
Page 9 Maintenance Manual DG-808C Section content page 2 Inspections 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 2.5 Inspection procedure for the controls ............ 2.7 3 Maintenance 3.1 General maintenance ................
Page 10 Maintenance Manual DG-808C Section content page 4.17 Installation and removal of the powerplant ........4.24 4.18 Removal and assembly of the engine doors........4.31 4.19 Securing the propeller bolts ............. 4.32 4.20 Checking the Ignition unit ............... 4.33 4.21 Installation and removal of the extension/retraction unit ....4.36 4.22 Calibration of the fuel display in the DEI-NT .........
Page 11 Maintenance Manual DG-808C Diagrams Elevator control circuit, trim Rudder control circuit Aileron, wing flap and airbrake control circuits, fuselage side Flaperon and airbrake control circuits, wing side Tow hook, water ballast system Tow hook, water ballast system from ser. no. 8-373 on Static and pitot system Placards DG-808C Classic Placards DG-808C Competition...
Page 12: Airworthiness Limitations
Maintenance Manual DG-808C 0.4 Airworthiness limitations 0.4.1 Repairs Repair or replace damaged parts prior to next flight. Follow the instructions of the DG-800B repair manual for repairs of the airframe. Repairs exceeding those as defined as minor damage in the DG-800B repair manual section 2 and major repairs must be accomplished at a certified repair station or by a certified mechanic rated for composite aircraft structure work in accordance with DG repair methods.
Page 13: Service Time, Maintenance Documents Of Equipment And Components
Maintenance Manual DG-808C f) 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. g) Flexible fuel bags in the wings (option) Type Uniroyal (rubber): these will have to be exchanged after 10 years.
Page 14: System Description And Adjustment Data
Maintenance Manual DG-808C 1 System description and adjustment data 1.1 Wing and tailplane setting data Wing: Sweep back (Leading edge): 0 + 3 mm (+ 0.12 in.) at wing taper change Dihedral (Leading edge line): 2.5° = 196 mm (7.72 in.) at wing taper change (y = 4.5 m) Angles of Incidence: -1°...
Page 15: Elevator Control And Trim System
Maintenance Manual DG-808C 1.2 Elevator control and trim system 1.2.1 Control system see diagram 1 1.2.2 Elevator deflections and tolerances 46 + 2 mm 1.81 + 0.08 in. down: 46 + 2 mm 1.81 + 0.08 in. measured at 134 mm (5.3 in.) from hinge axis which is directly at the edge of the cut-out for the rudder.
Page 16 Maintenance Manual DG-808C 1.2.3 Elevator stops The elevator stops are located at the base of the control 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 +1.5 mm (+0.06 in.).
Page 17: June
Maintenance Manual DG-808C 1.2.6 Repair of the automatic trim mechanism Bowden cable In the event of a replacement Bowden cable being installed, it should be emphasised that the cable must pass between the two parallel arms of the Control column mechanism as shown in the sketch. correct wrong If the cable passes outside the mechanism...
Page 18: Rudder Control
Maintenance Manual DG-808C 1.3 Rudder control 1.3.1 Rudder control circuit see diagram 2 1.3.2 Rudder deflections and tolerances 155mm (6.5 inch) (28°) +0, -5mm (-.2 inch) measured at 318 mm (12.52 inch) from the hinge axis. 1.3.3 Rudder stops The rudder stops are located at the lower hinge pedestal and can be adjusted with an Allen key wrench.
Page 19: Aileron And Wing Flap Control
Maintenance Manual DG-808C 1.4 Aileron and wing flap control 1.4.1 Control circuit see diagrams 3 and 4 A spring at the mixer shaft 8St70 provides additional aileron return force at positive wing flap settings. Note: The bearing of 6St9 on 6St15 see diagram 3 must not be greased (Teflon bearing).
Page 20 Maintenance Manual DG-808C 1.4.5 Complete readjustment Should it be necessary to completely reset the flap and aileron control, proceed as follows: Place the fuselage with the centre line horizontal see sect. 1.1. Fix the mixer shaft 8St70 (see diagram 3) in horizontal position. horizontal 8St70 then:...
Page 21: Airbrake Control, Wheelbrake
Maintenance Manual DG-808C 1.5 Airbrake control, wheelbrake 1.5.1 Control circuit see diagrams 3 and 4) The wheelbrake cable is connected to the airbrake torsion shaft (part 8St12). 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.).
Page 22: Undercarriage
Maintenance Manual DG-808C 1.6 Undercarriage 1.6.1 Main undercarriage 1.6.1.1 Control circuit, undercarriage Undercarriage control circuit see diagram 15, undercarriage see diagram 16 1.6.1.2 Adjustment a) Should the undercarriage not retract fully, an adjustment can be made by screwing out the universal rod end on pushrod 8FW47 with a 13 mm open end spanner.
Page 23: Tow Hooks
Maintenance Manual DG-808C 1.6.4 Hydraulic brake system (Option) a) Brake fluid approved specification DOT 3, DOT 4, SAEJ 1703. The brake fluid must be exchanged at least every 4 years. Warning: brake fluid is poisonous. b) Adjustment: see section 1.5.2c) If adjustment does not increase the braking effect as desired, the brake system is leaking or there is air in the brake system.
Page 24: Water Ballast System
Maintenance Manual DG-808C 1.8 Water ballast system 1.8.1 Water ballast release circuit see diagram 5 1.8.2 Wing tanks Version DG-808C Classic: double wall bags with a capacity of 50l per wing. Version DG-808C Competition: double wall bags with a capacity of 60l (15.85 U.S.
Page 25: Massbalance And Weights Of Control Surfaces
(0.60) (0.48) (0.231) (0.183) Caution: Before any changes to the massbalance weights are made, contact the DG Flugzeugbau factory. Method for determining control surface moments All control surfaces: Remove the control surface and hang it friction free on two hinge points.
Page 26: Fore And Aft Play Of The Wings
Maintenance Manual DG-808C 1.10 Fore and aft play of the wings 1.10.1 At the fuselage a) With the aircraft fully rigged, move the wings fore and aft to determine at which lift pin the most play exists. b) Derig the glider. c) Screw out the lift pin and insert a distance washer (inside diameter 16.5 mm (.65 in.)) and screw in the pin again.
Page 27: Power Plant
Maintenance Manual DG-808C 1.11 Power Plant 1.11.1 Arrangement: see diagrams 8 and 9. You will find a part list with the designations and the reference numbers for the powerplant parts at the end of this manual. 1.11.2 Engine type, coolant The engine is a SOLO 2625 01 with electronic dual ignition and liquid cooling.
Page 28: Propeller
Maintenance Manual DG-808C 1.11.4 Propeller: KS-1G-152-R-122-( )-B, attachment bolts: six M 8 x 65 DIN 931 - 8.8, head with a 2 mm (0.08 in.) dia. hole for lockwiring. Tightening torque of the bolts - 2-2.5 daNm (15-18 ft lb). Propeller positioning (not with optional BBSA friction-centrifugal clutch): To assist in having the propeller stop in a vertical position during flight, the propeller should be positioned accordingly to the compression point of the...
Page 29: Propeller Brake
Maintenance Manual DG-808C 1.11.9 Propeller brake see diagram 13 a) manual activation: The brake cable can be adjusted at the adjustment screw at the rear end of the engine or directly at the screw nipple at the brake lever at the engine. b) electrical activation (Option): The electric brake-motor acts on the same brake lever.
Page 30: Retraction - Extension Mechanism
Maintenance Manual DG-808C 1.12 Retraction - Extension Mechanism 1.12.1 Layout see diagram 10 1.12.2 The retraction-extension mechanism The retraction-extension mechanism (spindle drive) consists of a 12 V electrically driven sealed trapezoid screw shaft. A tension gas-strut is installed parallel to the spindle drive to compensate the engine weight. 1.12.3 Extension force of the gas-strut Time for extension approx.
Page 31: Fuel System
Maintenance Manual DG-808C Position engine retracted: Retract the engine via the ignition switch. When the propellermount touches the stop (at the upper part of the propellermount) the spindledrive should not be switched off, but should move the powerplant backwards a little before the position switch is actuated.
Page 32 Maintenance Manual DG-808C 1.13.3 Fuel pumps Electric fuel pump mounted in the fuselage centre section. This pump operates as soon as the ignition is switched on. In case the electric power is switched off via the master switch with running engine, the pump will receive electric power directly from the generator.
Page 33 Maintenance Manual DG-808C 1.13.7 Carburettor 1.13.7.1 Type Mikuni Membrane carburettor BN 38 Instead of a choke a fuel injection (primer) is installed. Normal position of the fine adjustment nozzle is fully anticlockwise (open). For high altitude operation the nozzle may be turned in clockwise direction (closed).
Page 34 Maintenance Manual DG-808C 2. Removal of the main nozzle: Loosen the 2 screws and lift off the cover plate with the rubber sealing Screw out the main nozzle. If it is necessary to remove the Tommy screw for cleaning you have to lift off the fine adjustment screw which covers the Tommy screw.
Page 35 Maintenance Manual DG-808C 1.13.8 Fuel injection (primer) The engine is equipped with a fuel injection system for engine start (primer) instead of a choke butterfly valve. The injection valve is positioned on the engine close to the carburettor. The injection pressure is provided by the electric fuel pump. Via a switch in the instrument panel the primer can be switched off or to automatic operation.
Page 36: Electrical System
To charge the batteries to their max. capacity such a charger with a max. output voltage of 14.4 V is required (most chargers supply only 13.8 V). A suitable charger Z 08 is supplied by DG Flugzeugbau. Caution: Don't charge longer than for 1 week.
Page 37 Maintenance Manual DG-808C 1.14.3 Control unit This aluminium box is located in the relay compartment. The control unit incorporates the following functions: 1. Master switch relays. 2. Control of the extension-retraction procedure. The extension-retraction relays are also mounted inside the unit. 3.
Page 38 Maintenance Manual DG-808C 1.14.6 Engine elapsed - time indicator: The engine time indicator is incorporated in the DEI-NT and counts as soon as the proximity switch detects that the propeller is turning and therefore counts only the pure engine running time. In addition the time to the next 25 hour maintenance will be displayed.
Page 39 Maintenance Manual DG-808C 1.14.10 Manual extension-retraction switch Manual extension and retraction is via one switch which is located on the instrument panel. When this switch is operated, the automatic extension/retraction system will be switched off. The automatic system will be switched on again when you operate the ignition switch. The manual switch activates the extension/retraction relays in the control unit directly, by-passing the safety functions.
Page 40 Maintenance Manual DG-808C 1.14.13 Circuit breakers and fuses 1. In the console of the instrument panel: a) Circuit breaker 2 A for electric variometers etc. b) Circuit breaker 3 A for the radio c) 3A for turn and bank or artificial horizon d) Circuit breaker 3 A spare eg.
Page 41 Maintenance Manual DG-808C 1.14.15 Proximity switch The proximity switch at the engine receives the switching pulses by the steel pins located at the upper drive belt pulley, see drawing 8M110 at the end of this manual. The proximity switch effects the following functions: 1.
Page 42 Note: If a new DEI-NT or a replacement DEI-NT should be installed, you have to report your actual elapsed engine time to DG Flugzeugbau to enable them to ajust the new DEI-NT to that value. Warning: With the connector plug disconnected from the DEI-NT, the ignition is not short-circuit.
Page 43: Pitot And Static System
Maintenance Manual DG-808C 1.15 Pitot and static system 1.15.1 Layout See diagram 6 1.15.2 Maintenance No special maintenance needed. 1.16 Ventilation and drain holes 1.16.1 Layout See diagram 171. 1.16.2 Maintenance No special maintenance needed. Issued: May 2012 TN800/41 1.30...
Page 44: Inspections
Maintenance Manual DG-808C 2 Inspections 2.1 Daily inspection see flight manual section 4.3 2.2 Regular inspections A Annual inspection  Execute all items of the daily inspection see flight manual section 4.3.  Check the rudder cables for wear especially around the S tubes on the rudder pedals.
Page 45 Maintenance Manual DG-808C 2.2 cont. B Special inspections Tow hook: After a wheel up landing, the tow hook mechanism is to be carefully checked for any damage. After a landing where the fuselage nose has touched the ground, the nose tow hook (Option) is to be cleaned and to be checked for correct functioning.
Page 46: Inspections After A Heavy Landing
Maintenance Manual DG-808C 2.3 Inspections after a heavy landing The whole aircraft Check that the tailplane is still properly aligned in the vertical and horizontal axis. Check the wing oscillating frequency with respect to previous checks. Wings Check the wing pins and bushes for any deformation - are there any white areas around the bushes? Root ribs Are there any cracks at the rib/wing skin joint or rib/spar joint? If so,...
Page 47 Maintenance Manual DG-808C Fuselage - fin intersection: Check for cracks. Remove gelcoat and any filler along the cracks. Apply pressure to the fin (push the fin towards the nose as well as applying torsion). Do the cracks penetrate the glass fibre structure? Disassemble the rudder and check the glued connection of the fuselage end bulkhead and the fin trailing edge web.
Page 48 Maintenance Manual DG-808C Instruments: Proper functioning? Dirt in the static ports or in the pitot probe? Engine compartment: Check for damage of the walls. Does the engine retract without scratching the side walls? Do the engine doors fit as well as before? Check the condition of insulation and fire resistant paint.
Page 49: Inspection Procedure For Increase Of Service Time
5. The results of the inspections have to be recorded in an inspection test report wherein comments are required for each inspection instruction. If the inspections are done outside the DG Flugzeugbau facilities, a copy of the records must be sent to DG Flugzeugbau for evaluation and information.
Page 50: Inspection Procedure For The Controls
Maintenance Manual DG-808C 2.5 Inspection procedure for the controls Check of flaperon and airbrake controls at the wing roots: Remove the plastic cap in the rear wing root rib. Insert a mirror with approx. 30 mm (1.2 in.) diameter in this access hole. Issued: September 2007 TN800/34...
Page 51: Maintenance
A block of hard wax has to be pressed against the rotating discs. By doing so, the wax becomes hot and is taken up by the cloth. The hard wax and the cloth discs should be purchased from the DG Flugzeugbau factory. Part-No. 70000121 Cloth disc Part-No.
Page 52: Maintenance Of The Airframe
Maintenance Manual DG-808C Plexiglas canopy: Small scratches on the exterior surfaces of the canopies can be removed by the "Schwabbel" procedure (see above). Lock the canopies to the fuselage! Metal parts: The pins and bushes for rigging the aircraft are not surface protected and must be covered with grease all the time (see section 3.3).
Page 53: Greasing And Oiling
Maintenance Manual DG-808C 3.3 Greasing and oiling Once a year your glider should be carefully checked and all bearings, including control surface hinges, should be cleaned and greased if necessary. The various greasing points are as follows:  Flaperon drive connections at the flaperon. ...
Page 54: Damage Of The Airframe
With major damage, contact the DG Flugzeugbau factory and send photographs and a damage report from a licensed inspector or from an appropriately rated mechanic.
Page 55: Servicing The Engine
Maintenance Manual DG-808C 3.5 Servicing the Engine Caution: If you don't operate the engine for periods longer than 2 months you must preserve your engine according to the instructions in the engine manual. The same applies for any overseas transportation. Caution: With an optional BBSA slipping-centrifugal clutch installed to the engine refer to Solo technical note No.
Page 56 Maintenance Manual DG-808C 5. Remove the carburettor cover and membrane, remove the needle valve, flush the carburettor by switching on the fuel pump. The fuel must spout out as a powerful stream. If a large amount of fuel leaks out of the carburettor when you remove the membrane this is a sign that: a) a dirt particle prevents the needle valve from closing completely or b) the main nozzle is clogged (dirty), so that the engine can't receive the...
Page 57 Maintenance Manual DG-808C 7. Check all fuel lines for any wear, kinks, tight fit and leaks. Check especially the fuel lines in the engine compartment, switch on the ignition to run the fuel pump. 8. Check the intake airfilter of the carburettor for excessive dirt and wear, wash with pure petroleum spirit and blow compressed air in reverse direction through the filter.
Page 58 Maintenance Manual DG-808C 13. Check the muffler for cracks and ensure mounting is secure. Check especially the cable which lifts the muffler during engine extension. Check the retaining cable for the muffler lifting cable incl. the rubber cord. Check the movable part at the front end of the muffler for cracks. Check the exhaust manifold (already removed) for cracks.
Page 59 Maintenance Manual DG-808C 16. Check the rubber engine mounts, especially for cracks. Therefore apply strong pressure to the propeller mount in forward, backward and sideways direction. 17. Check and grease the starter motor gear shaft (don't grease the starter motor gear) Check starter motor for tight mounting.
Page 60 Maintenance Manual DG-808C 26. Check the tension of the propeller bolts: remove the lockwire, loosen the propeller bolts and retorque them with a torque wrench, torque value see sect. 1.11.10. Secure again with lockwire according to section 4.19. 27. Check the propeller blades for any damage. 28.
Page 61: After 50 Resp. 100 Engine Hours
Maintenance Manual DG-808C 3.5.2 Every 3 years Section not effective (Exchange the coolant only every 6 years together with the coolant hoses, see sect. 3.5.5). 3.5.3 After 50 resp. 100 engine hours Without optional BBSA friction/centrifugal clutch: The drive belt has to be exchanged after 50 engine hours.
Page 62: Detailed Instructions For Assembly And Servicing Work
Maintenance Manual DG-808C 4 Detailed instructions for assembly and servicing work 4.1 Water-ballast system see diagram 5 or 5a from ser.no. 8-373 on Replacement of the water ballast bags: Unscrew the bolt attaching the Perlon line to the root rib and attach an additional 6 m (20 ft) long Perlon line dia.
Page 63: Replacement Of Control Circuit Cables
Maintenance Manual DG-808C 4.2 Replacement of control circuit cables The following cable connections are approved: 3.2 mm dia. control cable construction 7x19 with Nicopress-sleeves 28-3-M Copper and tool No. 51-M850 or 63-V-XPM or 64-CGMP where the M groove is to be used. The above applies to the rudder cables, the tow release cable and the engine retaining cable.
Page 64: Removal And Installation Of The Undercarriage (Main Wheel)
Maintenance Manual DG-808C 4.4 Removal and installation of the undercarriage (main wheel) 4.4.1 General Warning: A gas strut is installed outside the landing gear box to compensate the mass of the landing gear. The landing gear may retract by itself when unlocked by the force of the gas strut, especially when the glider is not in the normal position.
Page 65: Filling And Bleeding The Hydraulic Disc Brake (Option)
Maintenance Manual DG-808C 4.4.4 Filling and bleeding the hydraulic disc brake (Option) Caution: Filling and bleeding the system has to be done from the lowest point which is the brake cylinder assembly at the wheel. Otherwise the system can’t be bled completely. Necessary tools: 1.
Page 66 Maintenance Manual DG-808C lower the cylinder to it’s initial position. Rotate the cylinder so far, that the rear end of the cylinder comes lower than the front end. Continue filling the system with the cylinder in this position. fill the complete system up to 15 mm (0.6 in.) below the upper edge of the reservoir.
Page 67: Fixing Excessive Free Play Of The Canopy
Maintenance Manual DG-808C 4.5 Fixing excessive free play of the canopy Shrinking of the fibre reinforced plastic material may result in free play between the canopy hinge 8R48 and the canopy. You can fix the free play as follows: Take off the canopy and remove the emergency release spring. Tape the hinge completely and coat it with demoulding agent.
Page 68: Removal And Installation Of The Flaperons
Maintenance Manual DG-808C 4.6 Removal and installation of the flaperons 4.6.1 Removal of the flaperons 1. To remove the flaperons with unparted wings or to remove the flaperons from the 18 m wingtips you have to remove the tip parts (approx. 20 mm wide) from the flaperons.
Page 69: Control Surface Seals And Turbulators
Maintenance Manual DG-808C 4.7 Control surface seals and turbulators Note: To minimise the friction of the seals, the trailing edge of the seals should be chamfered. Apply a fine grinding paper (e.g. 400 grit) between sealing and control surface and move it up and down in spanwise direction to sand the trailing edge of the sealing.
Page 70 Maintenance Manual DG-808C 4.7.3 Flaperons To reduce the friction as far as possible a 38 mm (1.7 in.) wide selfadhesive Teflon coated glass fabric is glued on the upper side of the flaperon see sketch. Prior to removing the old fabric, mark its Teflon tape trailing edge with pencil on the flaperon surface.
Page 71 Maintenance Manual DG-808C Version with combi tape: Glue the Teflon glass fabric tape to the wing with 5mm overlap.. Version with dimple tape: Glue the Teflon glass fabric tape to the wing with 10mm overlap. Press the Teflon-glass fabric tape with a wooden stick into the gap between aileron and wing and glue the Teflon-glass fabric tape to the aileron surface.
Page 72 Maintenance Manual DG-808C 4.7.5 Horizontal tailplane a) Turbulator: 60° zig-zag turbulators are installed on upper and lower surface. Prior to removing the turbulators mark the position of the turbulator leading edge with a pencil on the stabilizer surface, otherwise see sketch: y measured from fuselage centre line 1 in.=25.4 mm a = up to leading edge Position...
Page 73: Determination Of The Moments Of The Flaperons
Maintenance Manual DG-808C 4.8 Determination of the moments of the flaperons Due to the flexibility of the flaperons and the large number of hinges it is very difficult to determine correct values for the moments. For the measurement you need a long flat working bench or a similar device. You must produce holders according to drawing 8V96 (enclosed in this manual).
Page 74: Working Instructions For Heat-Shrink Tubing
Maintenance Manual DG-808C 4.9 Working instructions for heat-shrink tubing To insulate various parts of the electrical system heat-shrink tubing is used. For repair and maintenance the heat-shrink tubing often has to be removed. For removal use a sharp knife. To insulate again slip a new piece of heat-shrink tubing over the part which is to be insulated.
Page 75: Replacement Of Wing Fuel Tanks (Option)
Maintenance Manual DG-808C 4.11 Replacement of wing fuel tanks (Option) Disconnect the plastic fuel line inside the wing at the quick connector attached to the wing root rib. Loosen the red black marked perlon cords at their attachment at the root rib. Attach an extension line 3 mm diameter (1/8 in.) 5 m long to the red line.
Page 76: Mounting And Tensioning Of The Drive Belt
Maintenance Manual DG-808C 4.12 Mounting and tensioning of the drive belt please refer to drawing 8M110 (enclosed in MM) a) Tensioning of the drive belt 1. Tensioning and loosening of the drive belt is accomplished by turning the eccentric axis 8M115, which carries the upper drive belt pulley, against the propeller mount (carbonfibre tower).
Page 77 Maintenance Manual DG-808C d) Initial setting of eccentric axis 8M115 If the marking was lost or if a new axis is to be installed, the eccentric must be positioned as follows: Remove the sealing cap 8M118/1. The groove in the front end of the axis shall point downwards. This is the lowest position of the eccentric.
Page 78 Maintenance Manual DG-808C Measuring the drive belt tension and tolerances please refer to drawing W57 (enclosed in MM) 1. Remove the left (in sense of flight) drive belt cover. 2. Insert the measuring tool W57 from the right hand side (inside) through the second threaded hole of the drive belt cover (counted from the upper end).
Page 79: Replacing The Bearings Of The Upper Drive Belt Pulley
Maintenance Manual DG-808C 4.13 Replacing the bearings of the upper drive belt pulley see drawing 8M110 (enclosed to this manual) a) Removing the bearings 1. Remove the propeller. 2. Remove the proximity switch. Its best to remove the switch together with its mounting plate 8M138.
Page 80 Maintenance Manual DG-808C 7. Place the pulley onto the shaft with care. It´s best if the powerplant is retracted so that the shaft is in vertical direction. 8. Put the rollers and the inner ring of the front bearing into place. Put on the antirotation securing washer and the first one of the KM4 nuts.
Page 81: Removal And Installation Of The Tension Gas-Strut
Maintenance Manual DG-808C 4.14 Removal and installation of the tension gas-strut (engine extension mechanism) a) Removal: 1. Take a piece of tube with 12mm (.47 in.) inside diameter and 80 mm (3.15 in.) length and cut it to receive two halfshells. 2.
Page 82: Replacement Of The Engine Retaining Cable
Maintenance Manual DG-808C 4.15 Replacement of the engine retaining cable Please refer to diagram 14. 1. Extend the powerplant. 2. Remove the access panel from the rear engine bay floor. 3. Remove the engine retaining cable from the propeller mount. Let the cable retract slowly, otherwise the retraction bungee may jump from its pulley located inside the rear end of the fuselage.
Page 83: Filling And Bleeding The Cooling System, Checking The Coolant
Maintenance Manual DG-808C 4.16 Filling and bleeding the cooling system, checking the coolant pump Please refer to diagram 9 Coolant: Commercially available anti-freeze for car engines (recommended: BASF Glysantin G48 Protect Plus concentrate) and distilled water. You will need approx. 1.8 liter , 0.475 US.gal.. With coolant pump type Webasto: mixing ratio 1:1 (up to approx.
Page 84 Maintenance Manual DG-808C 4.16.2 Removal of the coolant 1. Prior to removal of the coolant check the coolant pump see above, 2. Retract the engine until the engine doors just stay open. 3. Remove the straight hose connector GS 16 from the coolant hose on top of the coolant pump and replace it by a T-connector TS 16 (supplied with the glider service set).
Page 85: Installation And Removal Of The Powerplant
Maintenance Manual DG-808C 4.17 Installation and removal of the powerplant see diagram 8 4.17.1 Removal of the powerplant General notes:  Remove all Ty-raps (cable fasteners) which may hinder engine removal.  If necessary heat carefully all bolts secured with Loctite with a hot-air gun to enable easy removal.
Page 86 Maintenance Manual DG-808C I) Fully extend the powerplant (via the manual extension switch) 1. Remove the lockwire from the propeller mounting bolts and remove the six bolts with a 13mm socket wrench. Then pull off the propeller. 2. Removal of the engine bay doors, s. section 4.18. 3.
Page 87 Maintenance Manual DG-808C II) Retract powerplant almost completely 10. Disconnect the electrical connections at the firewall: a) Disconnect the multiple plug of the wiring set (from serial no. 8- 103 on installed in the firewall behind a cover plate). b) Only with EGT-option: Cut off the Ty-raps which secure the-2 plugs for the EGT probes and unplug the probes.
Page 88 Maintenance Manual DG-808C 4.17.2 Removal of the engine from the propeller mount General notes: Before removing the engine from the propeller mount screw four long bolts M10 resp. M12 into the 4 threads at the lower end of the engine block. This facilitates handling on the workbench because the powerplant can be placed on the bolts.
Page 89 Maintenance Manual DG-808C Disconnect the electric wiring coming from the magneto housing near the propeller brake. First remove the heat shrink tubing carefully with a sharp knife. Remove the mounting bolts and detach the starter motor. Disassemble the fuel lines from the primer to the carburettor at the carburettor using a small screwdriver to open the hose clamp.
Page 90 Maintenance Manual DG-808C Removal of the propeller brake: Unscrew the propeller brake fixing plate from the engine‘s rear side by removing three bolts with a 6 mm Allen key wrench. Close the opening of the exhaust manifold with tape and seal the airfilter with a plastic bag or similar.
Page 91 Maintenance Manual DG-808C 4.17.3 Reinstallation of the powerplant Reverse the procedures for removal mentioned above. Note sections 4.12, 4.14, 4.16, 4.19 and 4.21! Use only new selflocking nuts for reinstallation. Use Loctite 243 to secure all threads and bolts without selflocking nuts. Use new gaskets for the coolant outlet.
Page 92: Removal And Assembly Of The Engine Doors
Maintenance Manual DG-808C 4.18 Removal and assembly of the engine doors It is not necessary to cut the rubber cords for removal and assembly of the engine doors. a) Removal of the left engine door, e.g. for working at the carburettor: Extend the engine.
Page 93: Securing The Propeller Bolts
Maintenance Manual DG-808C 4.19 Securing the propeller bolts Use lockwire with min. 0.8 mm (0.03 in.) diameter. Secure the propeller bolts as follows: a) Slide the wire through the hole in the bolthead and bend it around the head. The wire should run tangential to the bolthead so that it secures the bolt clockwise to tighten it.
Page 94: Checking The Ignition Unit
Maintenance Manual DG-808C 4.20 Checking the Ignition unit Ducati-magneto generator Type P12W150 part no. 43171402 12V/150W with electronic boxes Ducati part no. 432372500 The engine has 2 independent ignition circuits. It is equipped with a DUCATI electronic C.D. ignition unit with magneto generator for supplying the electrical system of the aircraft.
Page 95 Maintenance Manual DG-808C b) If the malfunction remains on the same circuit, then carry on according to the following instructions: b)1 Check the shorting cables, see item 2. b). b)2 Checking the ignition, trigger and charging coils Disconnect the connector plugs from the electronic boxes see 1.
Page 96 Maintenance Manual DG-808C Check the plug. Screw off the cover and check all pins visually and by carefully pulling at each wire. If no defect can be discovered, the control unit must be replaced. b) If the generator is overcharging the batteries: Check all terminals at the control unit.
Page 97: Installation And Removal Of The Extension/Retraction Unit
Maintenance Manual DG-808C 4.21 Installation and removal of the extension/retraction unit When installing the extension/retraction spindle drive proceed as follows: First, don’t tighten the bolt which connects the spindle drive to its front mounting block. Extend the powerplant to the position (see sketch). Then tighten the bolt.
Page 98: Calibration Of The Fuel Display In The Dei-Nt
Maintenance Manual DG-808C 4.22 Calibration of the fuel display in the DEI-NT (only necessary with replacement or repair of the DEI-NT) 1. Preparations: Drain the fuselage tank using the built-in electrical fuel pump. Therefore disconnect the fuel hose at the lower side of the mechanical fuel pump and stick it into an appropriate can.
Page 99 Maintenance Manual DG-808C Calibration of the primer PRIMER DOSE: % of the max. amount of fuel injected by the primer, max. 99% - standard value 99%. (With 0°CHT. the adjusted amount of fuel will be injected. The amount of fuel will be reduced linearly to 0 at 40° CHT). PRIMER DURATION: Post starting injection of the primer, max.
Page 100: Weight And Balance
Maintenance Manual DG-808C 5 Weight and balance 1. Assemble the glider completely with gear down. 2. Empty fin ballast box and water ballast tanks, retract the engine, close the canopy. 3. Place scales under the tailwheel and if suitable scales are available under the main wheel.
Page 101 Maintenance Manual DG-808C Datum (BE): Wing leading edge at root rib Levelling line: Aft fuselage boom slope 1000:37 (tail down) pattern 1000:37 Moment arms of pilots and equipment see flight manual sect. 6.9 Empty weight C.G. c After the addition or deletion of equipment or accessories, repairs, painting, or any change in the aircraft that could influence the weight and balance;...
Page 102: Instrumentation And Accessories List
Maintenance Manual DG-808C 6 Instrumentation and accessories list Air speed indicator (0 - 300 km/h, 165 kts) Type Manufacturer Certification No. Winter 6 FMS 4(diam. 80mm) TS 10.210/15 0-300 km/h Ident.No. 6421369 0-160 kts Ident.No. 6423369 Winter 7 FMS 4(diam. 58mm) TS 10.210/19 0-300 km/h Ident.No.
Page 103 Maintenance Manual DG-808C Compass Manufacturer Type Certification No. B - 13 FD 19/77 Ludolph FK 16 10.410/3 Airpath C 2300 Airpath C 2400 P Hamilton H I 400 TSO C 7c Type1 Bohli 46 MFK 1 (only as additional equipment.) The compass should be compensated in the A/C.
Page 104 (RPM, fuel, CHT, voltmeter, engine elapsed time, outside air temperature, EGT as an Option) Type Manufacturer DG Flugzeugbau DEI-NT-DG808C Instruments which are not part of the minimum equipment: Transponders: Transponders certified for aircraft use according to TSO or JTSO or ETSO standards may be installed.
Page 105: List Of Special Tools
Maintenance Manual DG-808C 7 List of special tools A Special 13 mm wrench for front tailplane mounting screw (supplied with the glider) (W 35). B Pin 6 mm diameter with handle for wing tip mounting (W 36) (only with option wing parting) C Open end spanners D Allen key wrench: 5 mm, 6 mm, 8mm, 10mm, 12mm E Wrenches for slotted nuts (hook spanner) according to drawing W 51...
Page 106 Maintenance Manual DG-808C M Wrench for spark plugs 21 mm (13/16 in.) N Without Option BBSA Slipping/centrifugal clutch: Puller assembly for lower drive belt pulley according to drawing W40 Option BBSA Slipping/centrifugal clutch: Puller assembly for lower drive belt pulley according to drawing W60 O To fill the wing tanks: Hose with outside diameter 25 mm (1 in.) appr.
Page 107: Partlist
Maintenance Manual DG-808C 8 Partlist In this list you will find only parts of the powerplant, the electrical system and control surface sealings and turbulators. Please find the part no's of the control-system parts and of the metal fittings of the powerplant in the following diagrams.
Page 108 Maintenance Manual DG-808C Cooling system 60001201 Electric water pump Webasto U4810 modified (no longer available) 40863140 Replacement kit coolant pump Pierburg according to drawing 8R314, see TN 800/41 instruction 1. Caution: Respect the changed coolant mixing ratio, see section 1.11.2! 60001209 Coolant pump Pierburg 02058.50.0 (spare part for 4086314, not for first exchange against type Webasto!)
Page 109: Parts For The Electrical System
Maintenance Manual DG-808C 8.2 Parts for the electrical system 60510891 Battery 4E15 6V, 10 or 12Ah equipped with screw - terminals 40876200 DEI-NT-8E620 40876210 Control unit-NT 8E621 60510464 Limit-switch engine retracted and engine extended 164-574 alternatively SI2010-B2T20YR30,5m 60510506 Manual extension-retraction switch MTG 106 G 60510854 Key switch 3 Pos, 2 Pol KL09-1908KA (Master switch) 60510370...
Page 110: Control Surface Sealings And Turbulators
Maintenance Manual DG-808C 8.3 Control surface sealings and turbulators 1. Wings - upper surface 30003124 Mylar sealing 0.19 x 22 mm without glue, not curved, 2 x 5.64 m long 30003125 Mylar sealing 0.19 x 22 mm without glue, curved, 2 x 2.7 m long 70000253 Tesafix No.
Page 111: Enclosures
Maintenance Manual DG-808C 9 Enclosures 9.1 Equipment list 1 kg = 2.2046 lbs 25.4 mm = 1 in. mass arms date of date of Subject type installation removal Airspeed indicator Altimeter Variometer el. Variometer Compass Radio Engine Indicator DEI-NT and OAT gauge DG-808C C.
Page 112: Checklist For Checks And Maintenance Work
Maintenance Manual DG-808C 9.2 Checklist for checks and maintenance work according to sect. 3.5.1 of the maintenance manual 250 275 executed place date engine signature Each item shall be signed off or the data which was determined shall be entered. The list is valid for the engine hour range:..h - ..h DG-808C Ser.no.
Page 135 diluter demand pressure gauge...
Page 146 201/0,4/L=30cm 202/0,4/L=30cm Trennstelle ca. 47cm vom Benzinpumpenanschluß Connection approx. 47cm from socket 1N4007 RT/L=15cm 203/0,4/L=235cm rechtes Kraftstoffventil right fuel valve 0,4/L=52cm SW/L=15cm Flügeltankumschalter 0,4/L=52cm 10/0,4 wing tank selector switch 0,4/L=52cm RT/L=15cm 204/0,4/L=235cm linkes Kraftstoffventil left fuel valve SW/L015cm 1N4007 gelbe Anzeigelampe yellow lamp 207/0,4/L=52cm 001/0,4...
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Page 152 Enclosure 1 for maintenance manual Instruction for downloading log book and service data from the DEI-NT 1) Hardware requirements: - serial data cable (zero modem cable, 9 pin) - pc with terminal program (e.g. hyperterminal) 2) Transfer of data from DEI-NT to PC (Example for Windows / hyperterminal): a) switch off PC and glider master switch b) connect zero modem cable...
Page 153 Enclosure 1 for maintenance manual p) The data transfer can now been started by pushing the selector knob, RUN appears on the screen. q) The data transfer may be cancelled by pushing the selector knob, while the data transfer is in progress. r) After the data transfer is complete, the DEI-NT beeps briefly.
Page 154 Enclosure 1 for maintenance manual control unit over temperature warning (Y/N) Failure messages: Extension-retraction unit fuse blown (Y/N) Switch error warning (Y/N) Generator failure (Y/N) Primer failure (Y/N) Propeller brake failure (Y/N) Water pump failure (Y/N) Refuelling pump failure (Y/N) Fuel pump failure (Y/N) Verifying the messages: Engine speed limit exceeded acknowledge (Y/N)
Page 155 Enclosure 2 for Maintenance Manual DG-808C Instructions for transponder installation All dimensions mm, 25.4 mm= 1 in. For the installation refer to the drawing on page 4. Required materials: - Transponder - Transponder aerial Honeywell KA 60 - Mounting plate for aerial (supplied with aerial) - Aerial cable AIRCELL 7, Length 3500 mm - HF-Connector TNC for AIRCELL 7 aerial cable - BNC-Connector for AIRCELL 7 aerial cable...
Page 156 Enclosure 2 for Maintenance Manual DG-808C 2. Feeding through of the aerial cable In order to feed the aerial cable through, the following parts need to be removed: - instrument panel cover - relay compartment cover - oxygen bottle tube - baggage compartment covers (bottom and back) The aerial cable is delivered over length without terminals.
Page 157 Enclosure 2 for Maintenance Manual DG-808C Aerial in the engine bay 3. Installation of the transponder Mount the transponder in a suitable place on the instrument panel. In case of a transponder with separate control unit the control unit may be installed in the right hand cockpit side panel.
Page 159 solo Technische Mitteilung Seite 1 von 4 Service Bulletin Page 1 from 4 KLEINMOTOREN GMBH Nr. 4600 – 2-2 Postfach 60 01 52 , D 71050 Sindelfingen Kennblatt Nr. 4600 Ausgabe 16. März 1998 Type Certificate Data Sheet No. 4600 issued March 16 , 1998 Gegenstand Prüfung und Änderung der Rutschkupplung bei den Motoren 2 625 01 und 2 625 02...
Page 160 Solo Technische Mitteilung Seite 2 von 4 Service Bulletin Page 2 from 4 KLEINMOTOREN GMBH Nr. 4600 – 2-2 Postfach 60 01 52 , D 71050 Sindelfingen Maßnahmen Inspektion der Rutschkupplung und Einbau der neuen Abdeckscheibe Nr. 2042888 Betriebszeit Betroffen Maßnahme Intervall Baureihen...
Page 161 solo Technische Mitteilung Seite 3 von 4 Service Bulletin Page 3 from 4 KLEINMOTOREN GMBH Nr. 4600 – 2 - 2 Postfach 60 01 52 , D 71050 Sindelfingen Material Eventuel benötigte Ersatzteile für die Rutschkupplung (Spareparts fort he slip-clutch) 20 42 888 Abdeckscheibe Cover plate...
Page 162 solo Technische Mitteilung Seite 4 von 4 Service Bulletin Page 4 from 4 KLEINMOTOREN GMBH Nr. 4600 – 2 - 2 Postfach 60 01 52 , D 71050 Sindelfingen Bild 2 (picture 2) Kontakt für Ersatzteilbestellung (contact for spare parts): Anforderungen für Ersatzteile wie z.B.
Page 163 DG Flugzeugbau GmbH Service Info 69-10 DG-800B, DG-808C, DG-500MB Adjustment of propeller after jump of drive belt If during engine retraction the approx. propeller can’t be stopped in the 20 mm vertical position, the relation between (0.79 in.) propeller and motor must be checked.

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Dg-808c

DG Flugzeugbau DG-800A Maintenance Manual

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1 System Description and Adjustment Data

June

2 Inspections

3 Maintenance

4 Detailed Instructions for Assembly and Servicing Work

5 Weight and Balance

6 Instrumentation and Accessories List

7 List of Special Tools

8 Partlist

9 Enclosures

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