DG Flugzeugbau DG-1000T Maintenance Manual
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DG Flugzeugbau DG-1000T Maintenance Manual

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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
INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
Type:
DG-1000
Variant
DG-1000T
Data Sheet No.: EASA.A.072
Factory Serial No.:
Registration No.:
Date of Issue:
M A I N T E N A N C E M A N U A L
F O R T H E
M O T O R G L I D E R
DG-1000T
__________________________
__________________________
June 2005
0.0

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  • 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 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS...

  • Page 2: General

    Maintenance Manual DG-1000T 0 General 0.1 Manual amendments No. Page Description Date 0.3, 0.6, 0.10, 1.22, TN1000/09 October 1.23, diagram 15a 2006 0.5, 0.6, 8.2, ÄM1000-1-07 December diagram 15a 2006 0.0, 0.3-0.6, 0.12, 1.1, TN1000/10 January 3.3, 4.2, 4.16, 4.17,...
  • Page 3 Maintenance Manual DG-1000T No. Page Description Date 12 0.2÷ 0.9, 0.9a, 0.10 ÷ 0.12, Manual revision TN1000/18 February 1.2, 1.5, 1.11, 1.14, 1.15, 2011 1.27 ÷ 1.29, 1.33, 2.1, 2.4 ÷ 2.6, 3.3, 4.8, 5.1, 6.1, 6.2, 6.4, 8.3, 9.2, diagr. 1, 9, 11, encl.
  • Page 4 Maintenance Manual DG-1000T 0.2 List of effective pages Section page issued replaced/ replaced/ replaced/ June 2005 January 2007 see manual amendments " " " " " June 2005 January 2007 Febr. 2011 Oct. 2014 " Febr. 2011 " Febr. 2011 0.9a...
  • Page 5 Maintenance Manual DG-1000T List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ 1.25 " 1.26 " " 1.27 Febr. 2011 1.28 " Febr. 2011 1.29 " Febr. 2011 Oct. 2014 1.30 " Oct. 2014 1.31 " May 2008 1.32...
  • Page 6 Maintenance Manual DG-1000T List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ 4.13 " Oct. 2014 4.14 " 4.15 " 4.16 " January 2007 4.17 " January 2007 4.18 " May 2008 4.19 " Oct. 2014 4.20 "...
  • Page 7 Maintenance Manual DG-1000T List of effective pages (continued) diagram issued replaced/ replaced/ replaced/ May 2004 Oct. 2010 Nov. 2001 Oct. 2014 July 2017 June 2005 Oct. 2014 Nov. 2001 Nov. 2001 January 2007 Nov. 2001 January 2007 March 2008 Not valid for 10-...

  • Page 8: Table Of Contents

    Maintenance Manual DG-1000T 0.3 Content Section content page 0 General Manual amendments ................0.1 List of effective pages ................ 0.3 Content ....................0.7 Airworthiness limitations ..............0.11 0.4.1 Repairs ..................0.11 0.4.2 Life time of the airframe .............. 0.11 0.4.3 Life time of components .............. 0.11 0.4.4 Service time, maintenance documents .........
  • Page 9 Maintenance Manual DG-1000T Section content page Tow hooks ..................1.12 1.7.1 Tow release circuit ............... 1.12 1.7.2 Adjustment ................... 1.12 1.7.3 Damages ..................1.12 1.7.4 Removing the tow hooks ............. 1.12 1.7.5 Rubber cords ................1.12 Water ballast system ................ 1.13 1.8.1 Wingtanks ..................
  • Page 10 Maintenance Manual DG-1000T Section content page 1.14 Fuel system ..................1.22 1.14.1 Layout ..................1.22 1.14.2 Tank ..................... 1.22 1.14.3 Refuelling ..................1.22 1.14.4 Excess fuel line ................1.22 1.14.5 Fuel pumps ................... 1.23 1.14.6 Fuel cock ..................1.23 1.14.7 Fuel filter ..................1.23 1.14.8 Fuel quantity indication ...............
  • Page 11 Maintenance Manual DG-1000T 4 Detailed instructions for assembly and servicing work Water ballast system ................4.1 Replacement of control circuit cables ..........4.2 Adjustment and servicing of the control circuit ........ 4.2 Inspection and adjustment of the airbrakes........4.3 4.4.1 Retracted position ................4.3 4.4.2 Overcentre locking moment and locking travel ......
  • Page 12 Maintenance Manual DG-1000T diagrams Elevator control, trim Rudder control Controls in the fuselage (Aileron and spoiler controls) Controls in the wings (Aileron and spoiler controls) Tow releases Water ballast system Waterballast system 10-101, from 10-128 on Landing gear, hydraulic wheel brake (Version without nose wheel) up to ser.

  • Page 13: Airworthiness Limitations

    12000 flight hours. The initial life time for the DG-1000T is 3000 flight hours and may be increased by inspections according to section 2.4 of this manual to 6000 h, 9000 h, 10000 h, 11000 h and 12000 h.

  • Page 14: Service Time, Maintenance Documents

    Maintenance Manual DG-1000T 0.4.4 Service time, maintenance documents Follow the instructions of the respective manufacturer: a) 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.

  • Page 15: System Description And Adjustment Data

    Maintenance Manual DG-1000T 1 System 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°...

  • Page 16: Elevator Control And Trim System

    Maintenance Manual DG-1000T 1.2 Elevator control and trim system 1.2.1 Control system see diagram 1 1.2.2 Elevator deflections and tolerances 27° u= 77 up to 79 mm (3.03 up to 3.11) down: 21° d= 61 up to 63 mm (2.40 up to 2.48) measured at 168 mm (6.61 in.) from hinge axis which is directly at the edge of...

  • Page 17: Elevator Control Circuit Free Play

    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-1000T can be trimmed up to higher speeds it is likely that the trim is not sufficient in circling flight.

  • Page 18: Pilot Force Reducing Rubber-Cord

    Maintenance Manual DG-1000T 1.2.6 Pilot force reducing rubber-cord The rubber cord 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.

  • Page 19: Rudder Control

    Maintenance Manual DG-1000T 1.3 Rudder control 1.3.1 Rudder control circuit see diagram 2 1.3.2 Rudder deflections and tolerances 28° up to 29° which is 160 up to 165 mm (6.3 up to 6.5 in.) to both sides measured at 330 mm (13 in.) behind the hinge axis (lower rear end of the rudder).

  • Page 20: Aileron Control

    Maintenance Manual DG-1000T 1.4 Aileron control 1.4.1 Control circuit see diagrams 3 and 4. 1.4.2 Deflections and tolerances Aileron deflections: 25° 71±2 mm (2.8 ± 0.08 in.) down 12° 34±2 mm (1.34 ± 0.08 in.) measured at 164 mm (6.46 in.) from hinge axis (at the aileron root) 1.4.3...

  • Page 21: Complete Readjustment

    Maintenance Manual DG-1000T 1.4.5 Complete readjustment Should it be necessary to completely reset the aileron control (e.g. after a repair), proceed as follows:  Rig the glider with the inboard wing panels only.  Place the fuselage with the centre line horizontal see sect. 1.1.

  • Page 22: Airbrake Control, Wheelbrake

    Maintenance Manual DG-1000T 1.5 Airbrake control, wheelbrake 1.5.1 Control circuit see diagrams 3 and 4 The wheelbrake is connected to the airbrake torsion shaft (part 10St105). 1.5.2 Adjustment a) Airbrake overcentre locking force: Adjustment according to section 4.4. The adjustment must be inspected once a year.

  • Page 23: Undercarriage

    Maintenance Manual DG-1000T 1.6 Undercarriage 1.6.1 Main wheel (Version without nose wheel) 1.6.1.1 Undercarriage control circuit see diagram 12 and 7 (inside landing gear box) In the retracted position the undercarriage is locked by an over centre device. In the extended position the lock is by a locking notch at pushrod 10FW38 in the rear...

  • Page 24: Main Wheel (Version With Nose Wheel)

    Maintenance Manual DG-1000T c) With TN1000/13 executed, standard from ser. no. 10-133 on:: Adjust the stop bolt in part 10FW74 so that dimension a will be between 14,5 and 15.5 mm (.57 in. and .61 in.) see diagram 18. Adjust the cable via the adjustment screw in part 10FW74 so that the locking pin disengages when retracting the landing gear.

  • Page 25: Main Wheel (Non Retractable Version)

    Maintenance Manual DG-1000T 1.6.3 Main wheel (non retractable Version) see diagram 9 This landing gear version is equipped with a drum brake instead of a hydraulic disc brake. 1.6.4 Hydraulic brake system a) Brake fluid approved specification DOT 3, DOT 4, SAEJ 1703.

  • Page 26: Tow Hooks

    Maintenance Manual DG-1000T 1.7 Tow hooks 1.7.1 Tow release circuit see diagram 5 1.7.2 Adjustment Check if both tow releases open fully. Adjustment at the bellcrank 10R32 in the rear cockpit. 1.7.3 Damages The ring muzzle of the C.G. hook should not be bent or ground down and should move easily.

  • Page 27: Water Ballast System

    Maintenance Manual DG-1000T 1.8 Water ballast system (Optional with 18m wingspan, standard with 20m wingspan) 1.8.1 Wingtanks 1.8.1.1 Water ballast release circuit see diagram 6 1.8.1.2 Adjustment For the dump valve in the closed position, there should be 1 mm (.04 in.) space between the 8 mm (.315 in.) diameter PVC rod from the dump valve, and the...

  • Page 28: Fin Tank

    Check the control cable at the operating handle too. If the cable or the lever is worn, further use of the fin tank is prohibited. Please contact DG Flugzeugbau for a detailed repair instruction.

  • Page 29: Ballast Box In The Fin

    Maintenance Manual DG-1000T 1.9 Ballast box in the fin 1.9.1 Inspection of the control light in the front instrument panel Slide one weight after the other into the rails of the box. Check with each additional weight if the correct amount of blinks is displayed.

  • Page 30: Massbalance And Weights Of Control Surfaces

    Maintenance Manual DG-1000T 1.10 Massbalance and weights of control surfaces After repairs or repainting the control surfaces weights and moments should not exceed the following limits: Control Weight Moment Spring balance Surface reading see in- structions below kg×cm (lbs.) (lbs.×in.) (lbs.)

  • Page 31: Fore And Aft Play Of The Wings

    Maintenance Manual DG-1000T 1.11 Fore and aft play of the wings 1.11.1 At fuselage a) Fore and aft play at the front wing suspension is acceptable and a design feature. b) The fore and aft play at the rear wing suspension shall not exceed 0.5 mm (0.02 in.) at each wing.

  • Page 32: Power Plant

    Maintenance Manual DG-1000T 1.12 Power Plant 1.12.1 Arrangement: see diagram 13. You will find a part list with the designations and the reference numbers for the powerplant parts at the end of this manual. 1.12.2 Engine: The engine is a SOLO 2350C with single magneto ignition and air cooling. For further engine specifications refer to the engine manual, see sect.

  • Page 33: Starter

    Maintenance Manual DG-1000T 1.12.6 Starter: Electric starter motor, type see section 8.1. 1.12.7 Ignition system: spark plugs; Electrode gap 0.5 mm (0.02 in.), type see section 8.1. Ignition coils: One coil per cylinder, type see section 8.1 1.12.8 Throttle cable connections The cables can be finely adjusted at the adjusting screws located at the intake manifolds (holders for the Bowden outers).

  • Page 34: Tightening Torques And Locking

    Maintenance Manual DG-1000T 1.12.10 Tightening torques and locking: All bolts on the engine which are not secured by selflocking nuts should be tightened according to the following: 20 N m ( 15 ft lb) 12 N m ( 9 ft lb) They should also be secured with Loctite 243.

  • Page 35: Position Switches

    Maintenance Manual DG-1000T 1.13.4 Position switches Position engine retracted: via a switch at the engine support, actuated by the engine. Position engine extended: via a switch at the spindle drive, actuated by the gas strut. Position for stopping the engine: via a switch at the spindle drive, actuated by the gas strut.

  • Page 36: Fuel System

    Maintenance Manual DG-1000T 1.14 Fuel system 1.14.1 Layout see diagram 15 or diagram 15a (with automatic fuel cock see section 1.14.6b) standard from ser. no. 10-77 on or optional according to ‘TN1000-09) 1.14.2 Tank Fuselage tank with 22 litres (5.8 US gal.) capacity which can be used down to at least 0.5 l (0.13 US gal.).

  • Page 37: Fuel Pumps

    Maintenance Manual DG-1000T 1.14.5 Fuel pumps Electric fuel pump mounted in the fuselage centre section. This pump operates as soon as the ignition is switched on. Min. fuel flow at the electric pump: 30 l / hour (7.9 U.S.gal. /hour). The fuel flow can be determined by disassembling the fuel supply line at the distributor near the carburettor and flowing 1 litre (.26 U.S.gal.) of fuel into a container.

  • Page 38: Carburettor

    Maintenance Manual DG-1000T 1.14.9 Carburettor 1.14.9.1 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 39 Maintenance Manual DG-1000T 1.14.9.2 Cleaning To clean the carburettor you should execute items 1 to 3. Switch on the ignition to clean the carburettor by the electric fuel pump. If the carburettor is clean, a jet of fuel will spurt out. In addition, the openings for idle and main nozzle have to be cleaned with compressed air.

  • Page 40: Fuel Injection (Primer)

    Maintenance Manual DG-1000T 1.14.10 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 carburettors. 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 41: Electrical System

    To charge the batteries to their max. capacity a charger with a max. output voltage of 14.4 V is required (most chargers supply only 13.8 V). A suitable charger No. Z 08 is supplied by DG Flugzeugbau. Note: Don't charge longer than for 1 week.

  • Page 42: Control Unit

    Maintenance Manual DG-1000T 1.15.3 Control unit This aluminium box is located in the engine bay at the right wall. 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.

  • Page 43: Socket

    Maintenance Manual DG-1000T 1.15.7 12 V Socket: A socket is located in the front and in the rear cockpit (behind the pilots right shoulder). It is used for: battery charging (main switch in charging position) to provide power for external accessories (main switch “on”).

  • Page 44: Starter Press Button

    Maintenance Manual DG-1000T 1.15.10 Starter Press Button The starter press button is located in the centre of the throttle handle and activates, via the interlocks, the starter relay in the control unit, see sect. 1.15.3. 1.15.11 Wiring The wire gauges are given in the wiring plan 108E102 at the end of the wire No.

  • Page 45: Circuit Breakers And Fuses

    Maintenance Manual DG-1000T 1.15.12 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) circuit breaker 3 A spare eg. for turn and bank or artificial horizon d) circuit breaker 3 A spare eg.

  • Page 46: Proximity Switch

    Maintenance Manual DG-1000T 1.15.14 Proximity switch The proximity switch at the engine receives the switching pulses by the steel pins located at the upper drive belt pulley. The proximity switch effects the following functions: 1. Activation of the retraction mechanism and indication in the DEI-NT 2.

  • Page 47: Connector Plugs Between Fuselage And Engine

    (with the manual extension-retraction switch see sect. 1.15.9 not operated). 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 adjust the new DEI-NT to that value.

  • Page 48: Inspections

    Maintenance Manual DG-1000T 2 Inspections 2.1 Daily inspection see flight manual section 4.3 2.2 Regular inspections A Annual inspection (and 100hr inspection – only for USA)  Execute all items of the daily inspection see flight manual section 4.3. ...
  • Page 49 Maintenance Manual DG-1000T A Special inspections C.G. Tow hook: After a wheel-up landing, the C.G. tow hook is to be cleaned and to be carefully checked for any damage. Fuselage nose: After a landing where the fuselage nose has touched the ground, the nose tow hook is to be cleaned and to be checked for correct functioning.

  • Page 50: Inspections After A Heavy Landing

    Maintenance Manual DG-1000T 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: Spar ends: Check the wing pins and bushes for any deformation - are there any white areas around the bushes?.
  • Page 51 Maintenance Manual DG-1000T 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 52 Maintenance Manual DG-1000T Controls: Check for proper functioning and condition of all controls and adjustment mechanisms (i.e. rudder pedal adjustment, tow release, air brake, control column and trim etc.). Instruments: Proper functioning? Dirt in the static ports or in the pitot probe? Engine compartment: Check for damage of the walls.

  • Page 53: Inspection Procedure For Increase Of Service Time

    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 54: Maintenance

    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 55: Maintenance Of The Airframe

    Maintenance Manual DG-1000T 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 56: Greasing And Oiling

    Maintenance Manual DG-1000T 3.3 Greasing and oiling A The contact surfaces of the canopies to the fuselage are to be rubbed with colourless floor-polish (canopy and fuselage side) to reduce grating noise in flight. Polish at the beginning of the flight season and then every month.

  • Page 57: Damage Of The Airframe

    Check for any small changes such as small holes, bubbles and uneven areas on any skin surfaces, as these signal that something may be wrong. 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 58: Servicing The Engine

    Maintenance Manual DG-1000T 3.6 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.
  • Page 59 Maintenance Manual DG-1000T 5. Check both carburettors independently: 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.
  • Page 60 Maintenance Manual DG-1000T 8. Check the intake air filters of the carburettors for excessive dirt and wear, wash with pure petroleum spirit and blow compressed air in reverse direction through the filter. Spray the outside with oil for filters with cotton fabric, reinstall the filter.
  • Page 61 Maintenance Manual DG-1000T 21. Check the engine retaining cables for wear and kinks. Check thimbles and bushes of the upper cable connection for wear. Check the adjustment of the retaining cable according to sect. 1.13.3. If necessary adjust the cables at the adjustment screws in the rear end of the engine bay.
  • Page 62 Maintenance Manual DG-1000T 3.6.2 After 200 engine hours After 200 engine hours the power plant must undergo a major overhaul. Apart from the items listed in section 3.6.1., the following items also need to be done: 1. Remove the power plant and remove the engine from the powerplant. Ship the engine to the manufacturer or an aircraft engine maintenance workshop approved by the manufacturer and by the authorities.

  • Page 63: Detailed Instructions For Assembly And Servicing Work

    Maintenance Manual DG-1000T 4 Detailed instructions for assembly and servicing work 4.1 Water ballast system see diagram 6 Replacement of the water ballast bags and servicing the dump valves: Unscrew the bolt attaching the perlon line to the root rib and attach an additional 5 m (17 ft) long perlon line dia.

  • Page 64: Replacement Of Control Circuit Cables

    Maintenance Manual DG-1000T 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 powerplant retaining cables.

  • Page 65: Inspection And Adjustment Of The Airbrakes

    Maintenance Manual DG-1000T 4.4 Inspection and adjustment of the airbrakes 4.4.1 Retracted position The airbrakes must retract at their outboard end first. When the airbrake cap is flush with the wing surface at the outboard end, the inboard end must be 2 - 4 mm (0.08 - 0.16 in.) above the wing surface.

  • Page 66: Overcentre Locking Moment And Locking Travel

    Maintenance Manual DG-1000T 4.4.2 Overcentre locking moment and locking travel Caution: Checks and installation must be done at room temperature (20 – 25° C). Please make sure that the wings have been warmed up or cooled down to this temperature. At other temperatures wrong measurement of the locking moment will occur.
  • Page 67 Maintenance Manual DG-1000T 2. Overcentre travel (angle) To determine the overcentre travel use again the tool, see above. Place the wing horizontal on stands, upside up. Place the tool on the airbrake control hook up at the wing root rib. Unlock the airbrake just so far that the airbrake does not unlock or lock again by itself.

  • Page 68: Removal And Installation Of The Undercarriage (Main Wheel)

    Maintenance Manual DG-1000T 4.5 Removal and installation of the undercarriage (main wheel) 4.5.0 General Warning: A gas strut is installed inside 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 69 Maintenance Manual DG-1000T C Removal of the lower landing gear fork 10FW11/1 1. Remove the main wheel see A. 2. Retract the landing gear. Warning: The landing gear will retract by itself when unlocked by the force of the gas spring! 3.
  • Page 70 Maintenance Manual DG-1000T F Removal of the front fork 10FW10/1 1. Remove the baggage compartment floor and the rear cover of the baggage compartment. 2. Remove the main wheel see A. 3. Remove the lower fork 10FW11/1 see C. 4. Remove the spring legs see D.
  • Page 71 Maintenance Manual DG-1000T H Removal of the front upper fork 10FW13/1 Remove the main wheel see A. Retract the landing gear. Warning: The landing gear will retract by itself when unlocked by the force of the gas spring! Disassemble the gas spring from the left side of the undercarriage box see 4.5.0.

  • Page 72: Undercarriage (Main Wheel), Version With Nose Wheel

    Maintenance Manual DG-1000T 4.5.2 Undercarriage (main wheel), Version with nose wheel see diagram 8 A Removal of the main wheel 1. Remove the bolt M 8 x 45 DIN 931-8.8 zn which secures the holder 5FW9 for the brake assembly to the front landing gear strut 5FW10.
  • Page 73 Maintenance Manual DG-1000T D Removal of the front landing gear strut 1. Remove the baggage compartment floor 2. Remove the main wheel see A 3. Screw out the front landing gear axis 5FW6 (spanner 13 mm) and pull it out towards the fuselage wall.

  • Page 74: Filling And Bleeding The Hydraulic Disc Brake

    Maintenance Manual DG-1000T 4.6 Filling and bleeding the hydraulic disc brake Note: The master cylinder is mounted in an horizontal position. Due to the position of the reservoir filling and bleeding of the system is only possible from the lowest point which is the brake cylinder assembly at the wheel.
  • Page 75 Maintenance Manual DG-1000T - Fill the complete system up to 15 mm (0.6 in.) below the upper edge of the reservoir, avoid over filling. - Close the bleeder valve at the brake calliper. - Use the second syringe to remove all brake fluid from the reservoir.

  • Page 76: Control Surface Seals And Turbulators

    Maintenance Manual DG-1000T 4.7 Control surface seals and turbulators Materials see section 8. 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 seal and control surface and move it up and down in spanwise direction to sand the trailing edge of the seal.
  • Page 77 Maintenance Manual DG-1000T 4.7.1.2 Lower surface The ailerons are to be sealed at the lower surface with 38 mm wide Teflon-glass fabric tape. The Teflon-glass fabric tape must be glued 10 mm (.4 in.) wide to the lower wing surface. PVC tape (19mm wide) is glued over the leading edge of the seal to protect the seal from coming loose.

  • Page 78: Wing Lower Surface

    Maintenance Manual DG-1000T 4.7.2 Wing lower surface Dimple tape is installed as turbulator. The leading edge of the dimple tape is located at distances b in front of the wing trailing edge. 1 in.=25.4 mm Position ....

  • Page 79: Vertical Tailplane

    Maintenance Manual DG-1000T 4.7.4 Vertical tailplane a) Turbulators First install the seals see b), as the turbulators have to be glued on top of the seals at the upper end of the fin. 60° zig-zag turbulators are installed on both sides.

  • Page 80: Working Instructions For Heat-Shrink Tubing

    Maintenance Manual DG-1000T 4.8 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 81: Working At The Powerplant

    Maintenance Manual DG-1000T 4.10 Working at the powerplant 4.10.1 Mounting and tensioning of the drive belts a) Tensioning of the drive belt 1. Tensioning and loosening of the drive belt is accomplished by turning the eccentric axis which carries the upper drive belt pulley.

  • Page 82: Mounting The Propeller

    Maintenance Manual DG-1000T 6. If you find any seizing marks inside of the aluminium clamp remove them with fine abrasive paper. 7. Prior to reinstallation apply a thin film of oil to the axis. 8. Reassembly is the reverse of removal.

  • Page 83: Removal And Installation Of The Fuel Tank

    Maintenance Manual DG-1000T 4.10.3 Removal and installation of the fuel tank 1. Drain the fuselage tank using the built-in electrical fuel pump. To accomplish this disconnect the fuel supply line at the distributor near the carburettor and stick it into an appropriate can.

  • Page 84: Replacement Of The Engine Retaining Cable

    Maintenance Manual DG-1000T 4.10.4 Replacement of the engine retaining cable Please refer to diagram 16 A Removal of the old cables 1. Extend the powerplant. 2. Remove the access panel from the rear engine bay floor. 3. Remove the engine retaining cables from the powerplant, to accomplish this remove the mounting bolt from the engine with 13mm spanners..
  • Page 85 Maintenance Manual DG-1000T C Replacement of the bungees (only when worn or damaged) 9. Remove the access panel from the rear engine bay floor. 10. Remove the tailwheel and the access cover in the tailwheel box. 11. Pull the bungee out of the tailwheel box and fix at the rear end of the fuselage 12.

  • Page 86: Removal And Installation Of Gas-Strut And Spindle Drive

    Maintenance Manual DG-1000T 4.10.5 Removal and installation of gas-strut and spindle drive Please refer to diagram 14 1. Extend the powerplant via the manual extension switch, don’t tighten the retaining cables. 2. Remove the engine retaining cable from the powerplant, to accomplish this remove the mounting bolt from the engine with 13mm spanners.

  • Page 87: Installation And Removal Of The Powerplant

    Maintenance Manual DG-1000T 4.10.6 Installation and removal of the powerplant See diagram 13 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 88 Maintenance Manual DG-1000T Disassemble the fuel lines from their fittings at the holder at the front left hand side of the engine bay. Connect both open nipples with a 15 cm (6 in.) long piece of fuel line to close them.
  • Page 89 Maintenance Manual DG-1000T 4.10.6.2 Removal of the engine from the engine mount Necessary tools: Socket wrenches: 9 7, 10, 13 mm Open end spanner 10, 12, 13 mm Allen key wrenches: 3, 4, 5 mm 1 wire cutter 1 sharp knife 1 roll insulating tape Extend the powerplant via the manual extension switch, don’t tighten the...
  • Page 90 Maintenance Manual DG-1000T 4.10.6.3 Removal of further parts from the engine Caution: Don’t execute for shipping the engine for repair or overhaul): Necessary tools Open end spanners: 9, 12, 19 mm Wrench for spark plugs 21 mm (13/16 in.) Allen key wrench: 4 mm...
  • Page 91 Maintenance Manual DG-1000T 4.10.6.4 Reinstallation of the powerplant Reverse the procedures for removal mentioned above. Refer to sections 4.10.6.1 and 4.10.6.3. Use only new selflocking nuts for reinstallation. Use Loctite 243 to secure all threads and screws without selflocking nuts.

  • Page 92: Removal And Installation Of The Engine Doors

    Maintenance Manual DG-1000T 4.10.7 Removal and installation of the engine doors Extend the powerplant completely via the manual extension switch. Remove the engine door spring. To accomplish this remove the spring pins from the pins of the front engine door hinges, press the spring and pull it off from the hinges.

  • Page 93: Dei-Nt Settings

    Maintenance Manual DG-1000T 4.11 DEI-NT settings 4.11.1 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. To accomplish this disconnect the fuel supply line at the distributor near the carburettor and stick it into an appropriate can.
  • Page 94 Maintenance Manual DG-1000T 4.11.2.2 Download of flight log and service data FLIGHTLOG  PC: Push the selector knob, N (no) will be displayed, rotate the selector knob Y (yes) will be displayed, push the selector knob to reset start the download of the recorded data. The PC must be connected to the serial interface (socket close to the radio).

  • Page 95: Weight And Balance

    Maintenance Manual DG-1000T 5 Weight and balance 1. Assemble the glider completely with gear down. 2. Empty ballast boxes in fin andCockpit (Option), empty water ballast tanks and fuel tank, retract the powerplant. 3. Place scales under the tailwheel and if suitable scales are available under the main wheel.
  • Page 96 Maintenance Manual DG-1000T Note for gliders with nose wheel: When weighing with 2 pilots the load W 2 will be negative. This means that you need a spring balance to determine W 2. Therefore push a pin through the hollow tail wheel axis.

  • Page 97: Instrumentation And Accessories List

    Maintenance Manual DG-1000T 6 Instrumentation and accessories list Air speed indicator (0 - 300 km/h, 165 kts) Manufacturer Type Certification No. Winter 6 FMS 4(diam. 80mm) TS 10.210/15 0-300 km/h Ident.No. 6421514 0-160 kts Ident.No. 6423514 Winter 7 FMS 4(diam. 58mm) TS 10.210/19...
  • Page 98 Maintenance Manual DG-1000T Compass Manufacturer Type Certification No. B - 13 FD 19/77 Ludolph FK 16 10.410/3 Airpath C 2300 Hamilton H I 400 TSO C 7c Type1 46 MFK 1 (only as additional equipment.) The compass should be compensated in the A/C. A deviation table must be installed if deviation is more than 5°.
  • Page 99 Maintenance Manual DG-1000T Variometer Type Manufacturer Certification No. Winter 5 StVM5 (diam. 58) TS 10.230/14 + 5 m/s Ident.No. 5451 +1000 ft/min Ident.No. 5452 + 10 kts Ident.No. 5453 Winter 5 STV 5 (diam. 80) TS 10.230/13 + 5 m/s Ident.No.
  • Page 100 Maintenance Manual DG-1000T 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. Installation of transponder and transponder antenna must be accomplished according to enclosure 2 for this MM or technical note DG-G-02.

  • Page 101: List Of Special Tools Etc

    Maintenance Manual DG-1000T 7 List of special tools etc. A Special tool with 6 mm thread (W38/2) for the securing of the tailplane and for the locking pins of the rear wing suspension. B Special tool W36 (or a suitable pin with 6mm diameter) for derigging of the outboard wings and for the cover plate of the ballast box in the fin.

  • Page 102: Partlist

    Maintenance Manual DG-1000T 8 Partlist In this list you will find only parts of the powerplant, the electrical system and control surface seals 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 103: Parts For Fuel System

    Maintenance Manual DG-1000T 8.2 Parts for fuel system 60507550 Drainer CAV 110 (1/8" NPT) Warning: Replace the seal ring of the drainer against part no. 60504402 prior to installation 60504402 Seal ring for drainer CAV 110 (for automotive fuel) 60507560...

  • Page 104: Parts For The Electrical System

    Maintenance Manual DG-1000T 8.3 Parts for the electrical system 60510898 Battery 12V 17Ah 41076000 DEI-NT-DG1000T 41076020 DEI-NT-DG1000T second unit (rear cockpit) 41076010 Control unit-NT 10E601 60510815 Limit switch 164-025 05 for positions engine extended and for stopping the engine 60510463...

  • Page 105: Control Surface Seals And Turbulators

    Maintenance Manual DG-1000T 8.4 Control surface seals and turbulators 25.4 mm= 1 in., 1 m = 3.2809 ft. 1. Wings - upper surface 30003125 Mylar seal 0.19 x 22 mm without glue, curved 70000253 Tesafix No. 4965, 9 mm wide, 50 m roll glue film 70000229 Tesafilm 4104 white, 19 mm wide, 66 m roll PVC tape 2.

  • Page 106: Enclosures

    Maintenance Manual DG-1000T 9 Enclosures 9.1 Equipment list 1 kg = 2.2046 lbs 25.4 mm = 1 in. Subject type mass date of date of installation removal Airspeed indicator front Airspeed indicator rear Altimeter front Altimeter rear Variometer front Variometer rear el.

  • Page 107: Checklist For Checks And Maintenance Work

    Maintenance Manual DG-1000T 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.
  • Page 118 Bauteil Nr.: placards DG-1000T part no. of component DG Flugzeugbau GmbH Cockpit Check at all parts Type: DG – 1000T Serial No.: 10- Lead ballast (for under weight pilot)? Parachute worn properly? Typ: DG-1000T Year of construction: Safety harness buckled? W.Nr.
  • Page 125 Landing gear positive locking device diagram17 issued February 2008 TN1000/13 installation of the notch (LG extended) to 10FW12/2 direction of flight Installation of the locking catch. View LG retracted, locking catch not engaged...
  • Page 127 direction of flight cable to the limit switch gas strut not shown switch 1006.1511 (a) 10FW143 (a) bowden cable emergency LG extension spring_1,0x12x55_01 10FW121 10RU52 10FW130 10FW120 limit switch gas strut XGG2-88-S20Z1 10FW92 10FW93 10FW108 Detail E 10FW90 Schnitt A-A limit switch LG ext.
  • Page 128 Datenschilder elektrisch betätigtes Hauptfahrwerk DG-1000T placards electrically operated mainlanding gear DG-1000T Bedienelemente und Anzeigen für das elektrisch betätigte Fahrwerk im vorderen und hinteren Cockpit jeweils links oben im Instrumentenbrett Controls and control lights for the electrically operated landing gear in front and rear instrument panel (upper...
  • Page 131 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 132 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 133 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 134 Enclosure 2 for Maintenance Manual DG-1000T Instructions for transponder installation All dimensions in mm, 25.4 mm= 1 in. For the installation please refer to drawing on page 6. Required materials: - Transponder - Transponder aerial Honeywell KA 60 - Mounting plate for aerial (supplied with aerial)
  • Page 135 Enclosure 2 for Maintenance Manual DG-1000T In the engine bay, as a counterbalance to the aerial, the adhesive aluminium foil 400mm x 250mm has to be fitted according to the drawing and to picture 1). Before fitting the foil, degrease the engine bay surfaces with acetone.
  • Page 136 Enclosure 2 for Maintenance Manual DG-1000T Front control column: Aerial cable fixed to wiring harness picture 2 Now, follow the empty pipes on the right-hand side of the control column, leading into the instrument panel. Fix aerial cable every 200 mm to the wiring harness wherever possible with TY-raps, see picture 2.
  • Page 137 Enclosure 2 for Maintenance Manual DG-1000T A pipe clamp is mounted to the bulkhead, next to the spindle drive, holding the cable form. Unscrew the screw in order to attach another clamp (180° inverted to the original clamp), holding the aerial cable (see picture 4 ).
  • Page 138 Enclosure 2 for Maintenance Manual DG-1000T 3. Installation of the transponder Mount the transponder to a suitable place on the instrument panel. Connect the HF-Connector to the transponder. Power supply takes place through wire nr. 13(+),included in the wiring harness. Protection is then ensured via the installed circuit breaker (marked with XPDR).
  • Page 139 Enclosure 2 for Maintenance Manual DG-1000T Issued: June 2005 page 6 of 6...
  • Page 140 Enclosure 3 for maintenance manual DG-1000T Optional throttle handle in the rear cockpit TN1000/15 Service Instructions Part designations see MM diagram 19 and sketches below I. Bleeding the hydraulic system Necessary material: • Hydraulic fluid: Magura Blood Hydraulic Mineral Oil (don’t use brake fluid) Necessary tools: •...
  • Page 141 Enclosure 3 for maintenance manual DG-1000T Securing the terminal nipples Use lock wire with min. 0.8 mm diameter. The lock wire is necessary to prevent the connection from inadvertent opening. 12. Reinstall all parts. The clamp at the front cylinder must contact the lower flange of the cylinder.
  • Page 142 Enclosure 4 for Maintenance Manual DG-1000T Electrically operated main landing gear Part designations see MM diagrams 20 und 21 In the following text the changes to those sections of the maintenance manual which are effected by the installation of the electrically operated main landing gear will be given.
  • Page 143 Enclosure 4 for Maintenance Manual DG-1000T 1.6.5.2 Adjustment / limit switches With the electrically operated landing gear only the limit switches have to be adjusted a) Limit switch landing gear extended 1. Extend the landing gear electrically and check if the drag struts 10FW102 and the struts of the rear fork 10FW91 touch each other at their joint hinge point.
  • Page 144 Enclosure 4 for Maintenance Manual DG-1000T d) Switch emergency extension system (optional with TN1000/19, standard from ser.no. 10-157 on) This switch (position 20 in diagram 21) activates higher current for the spindle drive via the LG control unit to reset the gas-strut as long as one of the emergency extension handles is pulled.
  • Page 145 Enclosure 4 for Maintenance Manual DG-1000T 1.15 new subsection 1.15.18 Wiring see wiring plan 10E4 enclosed to the MM. Description of operation see AFM section 9.3. In the normal operating mode the landing gear will be retracted and extended by an electrical spindle drive.
  • Page 146 Enclosure 4 for Maintenance Manual DG-1000T Section 3 Maintenance 3.3 Greasing and oiling Subsection amended • Electrically operated landing gear: Clean and grease the slotted hole at the attachment of the spindle drive to the bell crank 10FW106 (see diagram 21).
  • Page 147 Enclosure 4 for Maintenance Manual DG-1000T 4 Remove bolt M6x32, which connects the lever 10FW89 to the shaft 10FW109. 5 Remove the axle with cone clamping devices 10FW124. To remove the axle hold the screw head with a spanner and unfasten the counter nut with an open end spanner until the axle can be pulled out.
  • Page 148 Enclosure 4 for Maintenance Manual DG-1000T 8 Slide the drive unit on the linear guide to the rear position. Be careful not to slide the drive unit too far so that it may slide off the linear guide. 9 Remove the 2 front bolts M6x28 which mount the linear guide to the landing gear box.
  • Page 149 Enclosure 4 for Maintenance Manual DG-1000T Section 8 Partlist new Subsection 8.5 Parts for the electrically operated landing gear 60000168 Lockable gas strut K0V2P-3-200-647-001/460N 41041400 Spindle drive completely assembled 60510463 Limit switch 164-(LG retracted) 60510464 Limit switch 164-574 (LG extended)
  • Page 150 : prior to next flight and upon changing the trim ballast in the ballast Reason : In a DG-1000T a foam rubber ring glued to the mounting plate of the optical sensors for checking the trim ballast has detached. This caused an indication error of the control lamp in the front instrument panel.
  • Page 151 Service Info DG Flugzeugbau GmbH Page 2 No. 67-07 76646 Bruchsal Assembly drawing for foam rubber rings 10L45/2:...

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