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DG Flugzeugbau LS4 Maintenance Manual

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Maintenance Manual LS4
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
DG FLUGZEUGBAU GMBH
Dipl.- Ing. W. Dirks
Issued: May 2011
0-1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only

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Summary of Contents for DG Flugzeugbau LS4

  • Page 1 Yours sincerely DG FLUGZEUGBAU GMBH Dipl.- Ing. W. Dirks Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 2: General

    14-3 ÷ 14-7 0-2, 0-4 - 0-6, 1-1, 2-2, 2-3, neo-Winglets TN4049 February 2-5, 2-17, 4-6, 7-3, 7-5 2019 Issued: February 2019 TN4049 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 3 Maintenance Manual LS4 Page intentionally left blank Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 4: List Of Effective

    Febr. 2019 “ Febr. 2019 “ “ Febr. 2019 “ “ “ “ “ 2-10 2-11 " 2-12 " Issued: February 2019 TN4049 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 5 " 4-15 " 4-16 " 4-17 " 4-18 " 4-19 " 4-20 " May 2011 " " " Issued: February 2019 TN4049 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 6 13-1 May 2011 14-1 May 2011 14-2 " 14-3 " 14-4 " 14-5 " 14-6 " 14-7 " Issued: February 2019 TN4049 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 7: Table Of Contents

    Canopy ..................... 1-9 1.9.1 Canopy LS4 and LS4-a............... 1-9 1.9.2 Canopy LS4-b ..................1-9 1.9.3 Canopy LS4-b standard, LS4 and LS4-a with TN4032 executed ..1-10 1.10 Instrument panel ..................1-10 1.10.1 LS4 and LS4-a instrument panel ............1-10 1.10.2 LS4-b instrument panel ..............1-10 1.11 Baggage compartment ................
  • Page 8 4.2.3 Gap sealings elevator ................4-7 4.2.4 Gap seals rudder ................. 4-7 4.2.5 Turbulator on lower wing surface ............4-8 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 9 Maintenance Manual LS4 Section Content……………………………………………………………..page Removal and installation of seat shell ............. 4-9 4.3.1 Removal and installation of seat shell LS4 and LS4-a ....... 4-9 4.3.2 Removal and installation of seat shell LS4-b ........4-9 Adjustment of water ballast valves ............4-11 Removal and installation of the wing water ballast bags: .....
  • Page 10 14.1 Annual inspection checklist ..............14-1 14.2 Instruction for maintenance of L’Hotellier ball and swivel joints ..14-4 Issued: May 2011 0-10 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 11: Airworthiness Limitations

    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 LS4, LS4-a and LS4-b is 12000 flight hours. Therefore inspections according to section 3.3 of this manual have to be executed at 3000 h, 6000 h, 9000 h and every 1000 hours following thereafter.

  • Page 12: Description Of Systems

    Caution: For operation with neo-Winglets (TN4049) the max. payload must not be reduced as with TN4045. The max. mass of the non-lifting parts is set to 250 kg / 517 lbs. for all LS4 variants (TN4046/4047 must be performed). The determination of the max. mass of the non-lifting parts in relation to the empty mass C.G.

  • Page 13: Aileron Control

    Note: The sketches for the control systems in the wings are to be found in section 1.7. LS4-b LS4 und LS4-a Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 14: Elevator Controls And Trim-System

    100% mass balance in vertical tail fin pushrod. 1.3.2 Trim Controls Trim handle at left hand cockpit wall behind landing gear handle- Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 15: Rudder Control System

    Rudder activated via steel cables guided in polyamide tubing,. 100% mass balance at rudder. 1.5 Wheel brake Feet operated, activated by bowden cable from rudder pedals. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 16: Air Brake Controls

    Note: The sketches for the control systems in the wings are to be found in section 1.7.3 and 1.7.4. LS4 und LS4-a LS4-b Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 17: Water Ballast System And Sketches For Wing Control Systems

    1.7 Water ballast system and sketches for wing control systems 1.7.1 Water Ballast System LS4 and LS4-a LS4 and LS4-a : Waterbags 4F5-13 (approx. 70 Liter <18.5 US gallons> per wing) or LS4-a optionally: 3F5-25 (approx. 85 Liter <22.45 US gallons> per wing), retrofit for LS4 see TN 4014.

  • Page 18: Water Ballast System Ls4-B

    Liters <0.92 US gal.> Water ballast system in wings LS4-b Water ballast System LS4-b in fuselage, optional fin tank Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 19: Wing Control Systems Ls4 And Ls4-A

    Maintenance Manual LS4 1.7.3 Wing control systems LS4 and LS4-a 1.7.4 Wing control systems LS4-b Friction damper Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 20: Cockpit

    After operating the canopy emergency release the canopy will be lifted at the front by the instrument panel, which is lifted by a gas strut. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 21: Canopy Ls4-B Standard, Ls4 And Ls4-A With Tn4032 Executed

    Maintenance Manual LS4 1.9.3 Canopy LS4-b standard, LS4 and LS4-a with TN4032 executed In case of an emergency exit, a spring loaded latch (LS-latch (Röger hook) for canopy emergency release ) at the rear canopy edge acts as a temporary hinge for clean separation of the canopy from the fuselage.

  • Page 22: Landing Gear

    Tail skid including cable deflector at front end or tail wheel optional. LS4-a, LS4-b LS4 with TN 4013 executed Parts list see next page Issued: May 2011 1-11 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 23: Wheel Brake

    4R2-119a lower adjustment screw 4R2-8 4R2-124a 1.14 Wheel Brake Feet operated; activated by Bowden cable from rudder pedals. Issued: May 2011 1-12 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 24: Hint For Working At The Control Systems

    17 mm / 0.67 in various versions possible M10 x 1 (Fine thread) 17 mm / 0.67 in PM 6 long Issued: May 2011 1-13 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 25: Pressure Ports

    ASI and altimeter only forward static pressure total pressure 1.16.2 Pressure ports LS4-b: Issued: May 2011 1-14 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 26: Drain Orifices

    TE probe (tota1 energy probe). Additionally 3 clear tubes without colour marking are installed from the vacuum bottle stowage compartment. Only LS4-b: Transparent dia. 6x1: upper front static pressure ports for very sensitive variometers or connected together with yellow line for electric variometers...

  • Page 27: Mass And Balance

    9. Calculate empty mass C.G. position for empty or non-existent vertical tail fin tank: net tail load * b Xcg= empty mass Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 28 (max. 170 kg <375 lbs.> water ballast) Caution: With TN4049 (neo-Winglets) executed, the max. take-off and landing mass will remain 472 kg / 1041 lbs. for variant LS4 and will be reduced to 505 kg / 1113 lbs.for variants LS4-a and LS4-b with neo-Winglets installed.

  • Page 29: Calculation Of Loading Limits, Example

    Note: With TN LS-S-01 the procedure to determine the max. mass of the non- lifting parts used for the LS4-b will also be allowed for the LS4 and LS4-a. Maximum mass of non-lifting parts may vary between 230 and 244 kg (507...
  • Page 30 Data Placard in cockpit in Flight Manual LS4-b, page 6-3, if fitted in tail fin Note for LS4 und LS4-a: If a fin battery may be installed, make a note on page 1-6. 6. For permanent installation of trim ballast mass see section 8.

  • Page 31: Examples For Calculation Of Loading Limits

    2.2.2 Examples for calculation of loading limits This sample is for an LS4-b, procede similar for the other variants. 1) Min. cockpit load (fin tank empty) With empty mass 255 kg/ 562 lbs and empty mass C.G. 665 mm/26,181 in The min.

  • Page 32: Empty Mass C.g. Range

    2.3 Empty mass C.G. range Note: With TN LS-S-01 the same in-flight C.G. limits as for LS4-a and LS4-b have been approved for variant LS4 too. So you will find only 1 set of tables valid for all variants in this manual.
  • Page 33 564 -699 564 -716 272 563 -611 563 -628 563 -646 563 -663 563 -680 563 -698 563 -715 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 34 564 -754 564 -773 564 -793 -813 -834 -856 563 -734 563 -752 563 -772 563 -791 -811 -832 -855 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 35 522 -646 522 -661 522 -678 521 -585 521 -600 521 -615 521 -629 521 -645 521 -660 521 -677 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 36 523 -727 523 -745 -762 -781 -800 522 -693 522 -709 522 -726 522 -743 -761 -779 -799 Issued: May 2011 2-10 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 37 22,28 -26,14 22,21 -24,09 22,21 -24,76 22,21 -25,43 22,21 -26,10 22,17 -24,06 22,17 -24,72 22,17 -25,43 22,17 -26,10 Issued: May 2011 2-11 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 38 22,28 -28,98 22,21 -26,81 22,21 -27,52 22,21 -28,19 22,21 -28,94 22,17 -26,77 22,17 -27,48 22,17 -28,15 22,17 -28,90 Issued: May 2011 2-12 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 39 22,21 -29,69 22,21 -30,43 22,21 -31,22 -32,01 -32,84 -33,70 22,17 -29,61 22,17 -30,39 22,17 -31,14 -31,93 -32,76 -33,66 Issued: May 2011 2-13 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 40 20,63 -24,88 20,59 -23,07 20,59 -23,66 20,59 -24,25 20,59 -24,84 20,55 -23,03 20,55 -23,62 20,55 -24,21 20,55 -24,80 Issued: May 2011 2-14 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 41 20,63 -27,36 20,59 -25,43 20,59 -26,06 20,59 -26,69 20,59 -27,32 20,55 -25,43 20,55 -26,02 20,55 -26,65 20,55 -27,28 Issued: May 2011 2-15 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 42 20,59 -27,95 20,59 -28,62 20,59 -29,33 -30,00 -30,75 -31,50 20,55 -27,91 20,55 -28,58 20,55 -29,25 -29,96 -30,67 -31,46 Issued: May 2011 2-16 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 43: Max. Mass Of Non-Lifting Parts

    Note: With TN LS-S-01 the procedure to determine the max. mass of the non- lifting parts used for the LS4-b will also be allowed for the LS4 and LS4-a. Caution: With TN4049 (neo-Winglets) executed, the max. mass of the non-lifting parts is 250 kg / 551 lbs.
  • Page 44 Table for <kg> and <mm> Empty Empty mass c.G. Xs <mm> from-up to / mass of non lifting parts <kg> mass <kg> Issued: May 2011 2-18 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 45 26.772 27.559 28.346 29.134 29.921 <lbs.> 22.008 22.795 23.583 24.370 25.157 25.945 26.732 27.520 28.307 29.094 29.882 30.669 Issued: May 2011 2-19 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 46 26.772 27.559 28.346 29.134 29.921 <lbs.> 22.008 22.795 23.583 24.370 25.157 25.945 26.732 27.520 28.307 29.094 29.882 30.669 Issued: May 2011 2-20 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 47: Calculation Of Max. Mass Of Non-Lifting Parts According To Tn 4046 With Water Bags V112 According To Tn 4047

    Table for <kg> and <mm> Empty mass c.G. Xs <mm> from-up to / mass of non lifting parts <kg> Empty mass <kg> Issued: May 2011 2-21 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 48 Table for <kg> and <mm> Empty mass c.G. Xs <mm> from-up to / mass of non lifting parts <kg> Empty mass <kg> Issued: May 2011 2-22 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 49 Maintenance Manual LS4 Calculation of max. mass of non-lifting parts LS4-b according to TN 4046 with water bags V112 according to TN 4047 cont. , empty mass up to 272 kg <600 lbs.> Maximum mass of non-lifting parts of 250 kg (551 lbs) may be increased in relation to empty mass and empty mass C.G.
  • Page 50 Maintenance Manual LS4 Calculation of max. mass of non-lifting parts LS4-b according to TN 4046 with water bags V112 according to TN 4047 on cont. , empty mass from 273 kg <602lbs.> on Table for <lbs.> and <in.> Empty mass c.G. Xs <in.> from-up to / mass of non lifting parts <lbs..>...

  • Page 51: Inspections

    5. Only LS4 and LS4-a: Check gap sealing tape on aileron upper side (textile tape) for existence and if tape has shrunk. Replace if necessary according to section 4.2.2.1.
  • Page 52 (flight performace!) and restore if necessary. Insatllation see section 4.2.5. 8. Check airbrakes a) Only LS4-b: Check air brake friction damper at outer side of air brake box for proper operation of damper rod and pads free from grease.
  • Page 53 4.9: Measure force to open canopy emergency release according to section 4.9. Only LS4-b: If this measurement or an operational check is performed without a helper, the spring at the LS-Latch (Röger hook) TN 4032 located at the fuselage becomes deformed and must be exchanged!.
  • Page 54 Maintenance Manual LS4 Annual Inspections continued 15. Only LS4 and LS4-a: L’Hotellier control quick connectors: Check connectors of ailerons and airbrakes. Secure connectors after connection by turning LS-sleeves over joints as far as possible. Check securing by trying to disassemble connectors with lock plate pressed down: Minor free play about 1 mm <0.4 in.>...

  • Page 55: Extraordinary Inspections After Heavy Landings

    - Wings, fuselage and tail for damage (cracks, buckling, compression) - Wing's oscillation number - Control surfaces function and deflections - Tangential tubes across fuselage for straightness Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 56: Inspection Procedure For Increase Of Service Time

    5. The results of the inspections have to be recorded in an inspection 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 57: Lubrication Schedule

    These bearings are used in the elevator system, aileron system and air brake system. Caution only LS4-b: The friction damper inside the air brake boxes prevents oscillations during extension of air brakes. Therefore, friction pads should never...

  • Page 58: Working Instructions

    4.1.1.1 Removal of ailerons - LS4 and LS4-a: Remove gap tape on upper surface. - LS4-b, LS4 and LS4-a optionally: Remove Teflon tape of gap sealing on upper surface. - If existing: Detach internal lower side sealing tapes (Teflon Tape) from aileron.
  • Page 59 4.2.1. - Bond fillet at aileron tip recess with contact adhesive (e.g. Pattex) - LS4 and LS4-a Reinstall sealing tape on upper side according to section 4.2.2 - LS4-b, LS4 and LS4-a optionally: Install new upper side seals if necessary according to section 4.2.3.

  • Page 60: Elevator

    - Remove internal sealing from stabilizer. 4.1.2.2 Installation of elevator - LS4-b, LS4 and LS4-a optional: Install internal seal on upper side of stabilizer according to section 4.2.1. - Grease bearings according to Lubrication Schedule, page section 3.4.

  • Page 61: Rudder

    6.4 Nm (0.64 daNm, 4.7 ft lbs).. Axial rudder movement should be audible. Maximum axial play 1 mm (0.04 in). - LS4 and LS4-a: Fix internal seals on both sides of rudder, see section 4.2.1. Issued: May 2011...

  • Page 62: Installation Of Control Surface Gap Sealings And Turbulators

    12. Mask rear edge of sealing tape with white PVC tape (12mm wide) to avoid warping. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 63: Gap Seals Aileron

    Note: Don’t pull the tape too tight as with time the tape will shrink. Remove residuals of adhesive with petroleum ether (pure petroleum spirit). 4.2.2.2 Gap seals aileron upper side LS4-b, optionally LS4 and LS4-a, necessary in case TN4049 was performed Mylar seals in combination with selfadhesive Teflon glas tape is used.

  • Page 64: Gap Sealings Elevator

    4.2.3.1 Gap seals elevator LS4 und LS4-a Apply tape (Tesaband 651 white 38 mm <1.5 in.> wide) with elevator deflected fully downwards. 4.2.3.2 Gap seals elevator LS4-b, optional LS4 und LS4-a Internal seal with Teflon tape on upper side, see section 4.2.1. 4.2.4 Gap seals rudder 4.2.4.1 Gap seals rudder LS4 und LS4-a...

  • Page 65: Turbulator On Lower Wing Surface

    Given measurements are from leading edge of turbulator to wing trailing edge in mm and inches. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 66: Removal And Installation Of Seat Shell

    Maintenance Manual LS4 4.3 Removal and installation of seat shell 4.3.1 Removal and installation of seat shell LS4 and LS4-a 4.3.1.1 Removal of seat shell LS4 and LS4-a - Disconnect the seat back at the base and the seat back adjustment cable at the left cockpit wall, swivel seat back out of the cockpit to the right hand side.
  • Page 67 Check especially function of release system: hook opening completely as well as clearance at T-shaped handle with landing gear down and locked. Issued: May 2011 4-10 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 68: Adjustment Of Water Ballast Valves

    3 mm (0.118 in). do not forget to counter lock nuts after adjusting Sketch for LS4-b Issued: May 2011 4-11 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 69: Removal And Installation Of The Wing Water Ballast Bags

    100 N <45 Ibs>. Note: The large waterbags 3F5-25 (installed in LS4-a) consist of 2 bags per wing which are connected via a tube running from the valve at the root through the inner bag to the outboard bag.

  • Page 70: Assembly Of The Wing Water Ballast Bags

    - Connect rope to intermediate rope in wing (if no longer connected) by stitching. - Check for presence of bonded-on gasket at valve discharge port. Issued: May 2011 4-13 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 71: Installation Of The Wing Water Ballast Bags

    Disassembly is required again to find and solve the problem in order to clear the plane for flight! Issued: May 2011 4-14 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 72: Removal And Installation Of The Tail Fin Water Ballast Tank (Option)

    Tightness during filling (back to front via funnel). With valve open, water level in filling tube must remain constant. Issued: May 2011 4-15 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 73: Removal And Installation Of The C.g. Hook

    Issued: May 2011 4-16 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 74 Maintenance Manual LS4 Removal and installation of the C.G. Hook cont. Section A-B Issued: May 2011 4-17 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 75: Removal And Installation Of The Nose Hook (Option)

    - Only LS4, LS4-a: remove rudder pedal assembly and trim weight holder. - Only LS4-b: disconnect trim weight holder from pedal guide >a< - Only LS4-b: disconnect 2 bolts >b< at front end of canopy support from bracket, move support as far back into cockpit as possible, perhaps disconnecting gas strut at one end as well.
  • Page 76 "Pilot" in seat, both canopy locking handles opened. One person at the front end to lift the canopy. Only LS4-b: The person at the front end should make sure that the canopy is not lifted too far up by the gas strut. Otherwise this would unduly deform the spring of the LS-Latch (Röger hook) located at the...

  • Page 77: Canopy Emergency Release

    When force is clearly lower, the spring must be exchanged to guarantee proper separation of canopy from fuselage during jettison. Issued: May 2011 4-20 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 78: Control Surfaces

    148mm 240 – 250 mm from reference point 5.83 in. 9.45 in. up to 9.84 in. Caution elevator: The values in mm / in. are only valid for LS4 and LS4-a. For LS4-b the values in mm / in. are to be found in section 5.5.

  • Page 79: Control Surface Weight And Mass Balance

    Measure load at trailing edge with reference line level Only LS4-b: Measure additionally radius from hinge line to measuring point, multiply load and radius to yield hinge moment. When using identical locations for measuring as used in final production inspection, only trailing edge load must be checked.

  • Page 80: Control Surfaces Free Play

    Elevator: maximum 1.5 N <0.331 lbs) at 30 mm <1.2 in.> below top end of control stick Aileron LS4 and LS4-a with fabric tape seal at upper side (see section 4.2.2.1): approx. 2 N <0.441 lbs> at 30 mm <1.2 in.> below top end of...

  • Page 81: Limit Values For Control Surface Deflections In Mm/In. ,Only Ls4-B

    Maintenance Manual LS4 5.5 Limit values for control surface deflections in mm/in. ,only LS4-b Elevator local radius down * up * mm/in 23°to 19° 24°to 30° 145 mm 241 to 251 mm 352 to 363 mm 5.709 in. 9.488 to 9.882 in.
  • Page 82 Maintenance Manual LS4 Limit values for control surface deflections in mm/in. ,only LS4-b cont. Rudder local radius 26°to 30° mm/in mm/in ' 309 mm 305 mm 137 to 158 mm 12.165 in 12.008 in 5.394 to 6.221 in 310 mm...
  • Page 83 Maintenance Manual LS4 Limit values for control surface deflections in mm/in. ,only LS4-b cont. Aileron local radius Down mm/in 13° to 15° 21° up to 25° 155 mm 35 to 40 mm 56 to 67 mm 6.102 in. 1.378 to 1.575 in. 2.205 to 2.6381 in.

  • Page 84: Special Tools

    Water ballast dump valve Version 2 (see sketch in section 1.7.1) Valve key 4F05-82 for removal and installation of the water valve from the wing dump outlet Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 85: Placards And Markings

    Maintenance Manual LS4 Placards and markings 7.1 Placards and markings LS4 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 86 Maintenance Manual LS4 Placards and markings LS4 cont. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 87: Placards And Markings Ls4-A

    With TN4049 neo-Winglets: Additional placard clearly visible at right cockpit wall to be installed below the data placard: Max. take-off mass 505 kg 1113 lbs. with neo-Winglets installed Issued: February 2019 TN4049 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 88 Maintenance Manual LS4 Placards and markings LS4-a cont. LS4-a Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 89: Placards And Markings Ls4-B

    With TN4049 neo-Winglets: Additional placard clearly visible at right cockpit wall to be installed below the data placard: Max. take-off mass 505 kg 1113 lbs. with neo-Winglets installed Issued: February 2019 TN4049 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 90 CanopyEmergency Release: open left side normally, Pull right side with approx. 15 kg/33 lbs. force to stop near right canopy opening handle Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 91: Permanent Installation Of Fixed Ballast And Equipment

    One mass of 2.45 kg <5.4 lbs> reduces the min. cockpit load by about 3 kg <6.6 lbs.>. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 92: Fixed Ballast At Rear Fuselage End

    2. Maximum weight of rear trim weight: approx. 2.45 kg <5.4 lbs>. (Part 4R8-109) Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 93: Permanent Installation Of Equipment In Baggage Compartment

    Caution: Don’t exceed the max. baggage compartment load of 5 kg (11 lbs.) with loose and permanently installed items. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 94: Instruments- And Equipment List (Master Equipment List)

    Ident.No. see 6FMS4 or other instruments approved according to TSO, JTSO or ETSO for use in aircraft. The ASI must have colour markings according to flight manual LS4 and LS4-a: page 1-3 and LS4-b section 2.3. Issued: May 2011...

  • Page 95: Altimeter

    TS 10.220/47 Airpath C 2400 P BS1, KJ-13A FD 19/77 Bohli 46 MFK 1 Not approved, only as additional system Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 96: Uhf - Transmitter And Receiver

    TCDS No. Apparatebau Gauting WZ 402/31 12V 10.241/8 Kelvin & Hughes KTS 0406 or KTS 0406 R TS 10.210/19 EZS-3 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 97: Thermometer

    The installation must be must be accomplished according to technical note DG-G-07. After installation a new weighing report must be filed. Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 98: Materials For Repair

    30781 Note: One layer of Polyester fabric should be replaced during repair with 2 layers of 92125. 10-1 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 99 + hardener. Application and mixing is identical as for cotton flocks. Issued: May 2011 10-2 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 100 Manufacturer: various reinorange RAL 2004 (orange) or RAL 3000 (red) Sources for material All materials can be obtained from the DG Flugzeugbau Factory. Issued: May 2011 10-3 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 101: Repairs

    When doubts arise as to the repair ability of damage, the DG Flugzeugbau factory should be contacted for further information. The information in this manual refers only to repairs of minor damage like holes in the underside of the fuselage resulting from a wheel up landing, or damage from hangar accidents etc, see section 2.

  • Page 102: Repairs Of Composite Structures, General

    Note: Special hints for handling FRP repairs are found in the Petite Plane Patch Primer (Author U. Hänle). Issued: May 2011 11-2 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 103: Tools And Facilities Required

    Therefore you may construct a tempering tent, using plastic film or Styrofoam plates. Issued: May 2011 11-3 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 104: Instructions For Frp Repairs

    Heat the area around the hole to approx. 60°C (140°F). Then tap the outer skin with a round headed hammer so that the foam is somewhat compressed. Apply the new cloth. Issued: May 2011 11-4 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 105: Repair Of Outer And Inner Skin Of A Sandwich Panel

    Final sanding with wet sandpaper grade 600 should finish the job. In more severe cases, one coat of gelcoat will remove all trace of the dent. Issued: May 2011 11-5 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 106: Outer Skin Finish

    Sand the inner skin and insert the corrugated cardboard with resin thickened with microballoons at the corrugated side. Then replace the outer skin. Issued: May 2011 11-6 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 107: Types Of Materials And Overlap Dimensions

    + 45° 15 mm / 0.59 in. foam core inner skin 92110 + 45° 15 mm / 0.59 in. Issued: May 2011 11-7 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 108 The overlap of the fuselage fabric to the fin is from the fuselage upper side 100 mm <3.94 in.> up the fin. Issued: May 2011 11-8 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 109: Control Cables And Connections

    Stop sleeve: Nicopress NT S117J (871-17-J), use tool groove "J" of tool 51-MJ 1-pressing. 3. Waterballast control cable to fin tank (LS4-b option) Cable: 1.2 LN9389 (stainless) resp. 1,25mm D construction 7x7 DIN3055 stainless steel 1.4401 Steel thimble: A 1.7...

  • Page 110: Longitudinal Motion Pushrod Bearings

    ! Issued: May 2011 11-10 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 111: Recommendations For Maintenance And Care Of Gelcoat Surfaces

    Caution : UP-gelcoat shows distinctive weathering marks due to changes of temperature, ultra violet radiation and humidity unless regularly polished with hardwax. 12-1 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 112: Schwabbel" Procedure

    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.

  • Page 113: Transport Of Sailplane

     Use an elastic cord from the tow hook and a helper at the wing tip  or use tail dolly with towbar and sprung wheel at one wingtip. 13-1 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 114: Appendix

    Thermometer function Air brake system Indication check L’H. Connectors * Place: _________ Date: ________ Stamp: __________ Signature: _______________ 14-1 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 115 ________ / Minute Tangential play Zero position of controls Place: _________ Date: ________ Stamp: __________ Signature: _______________ Issued: May 2011 14-2 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 116 Findings / Complaints / Remedy No. Findings Remedy / Repair Inspector Place: _________ Date: ________ Stamp: __________ Signature: _______________ Issued: May 2011 14-3 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 117: Instruction For Maintenance Of L'hotellier Ball And Swivel Joints

    Maintenance Manual LS4 14.2 Instruction for maintenance of L’Hotellier ball and swivel joints 14-4 Issued: May 2011 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 118 Maintenance Manual LS4 Instruction for maintenance of L’Hotellier ball and swivel joints cont. Issued: May 2011 14-5 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 119 Maintenance Manual LS4 Instruction for maintenance of L’Hotellier ball and swivel joints cont. Issued: May 2011 14-6 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 120 Maintenance Manual LS4 Instruction for maintenance of L’Hotellier ball and swivel joints cont. Issued: May 2011 14-7 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

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