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Glaser-Dirks DG-300 Maintenance Manual

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Maintenance Manual DG-300
Recommendations to order spare parts
Please try to determine the exact designations of the spare parts for your order
using the maintenance manual. This is to guarantee a fast and correct delivery of
the parts.
The designations are to find in the sections system description, instructions for
assembly and servicing work and especially in the diagrams of the maintenance
manual.
Yours sincerely
GLASER-DIRKS FLUGZEUGBAU GMBH
Dipl, Ing. W. Dirks
Issued: December 2009
0.0
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Manual valid with the up-to-date cover page only

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  • Page 1 Maintenance Manual DG-300 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.
  • Page 2 Description Date Combination of the initial December 2009 Maintenance Manuals of the Variants DG-300, DG-300 ELAN, DG-300 ELAN ACRO, DG-300 Club ELAN and DG-300 Club ELAN ACRO, new standardized format 0.7, 1.10, 1.12, 2.1, Miscellaneous changes to the December 2009 2.4, 3.2, 4.1, 4.2,...
  • Page 3 Maintenance Manual DG-300 Page intentionally left blank Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 4 Maintenance Manual DG-300 0.2 List of effective pages Section page issued replaced replaced replaced December 09 " " " " August 20 " August 20 " August 20 " August 20 August 20 December 09 " " " August 20 "...
  • Page 5 Maintenance Manual DG-300 List of effective pages (cont.) Section page issued replaced replaced replaced December 09 " " " " " " " December 09 " December 09 " " August 20 December 09 Diagrams December 09 " " "...

  • Page 6: Table Of Contents

    Maintenance Manual DG-300 0.3 Table of contents Section content page General ....................... 0.1 Amendments ................... 0.1 List of effective pages ................0.3 Table of contents ..................0.5 Airworthiness limitations ............... 0.8 0.4.1 Repairs .................... 0.8 0.4.2 Life time of the airframe ..............0.8 0.4.3...
  • Page 7 Diagram 5 Tow hook, water ballast release systems DG-300, DG-300 ELAN, DG-300 ELAN ACRO ..................8.5 Diagram 6 Tow hook, water ballast release systems DG-300 Club ELAN, DG- 300 Club ELAN ACRO ................8.6 Diagram 7 Empty weight centre of gravity range ..........8.7 Diagram 8 Placards DG-300 &...
  • Page 8 Maintenance Manual DG-300 Enclosures Installation sketch EFK ..................9.1 Installation sketch 3 ED ..................9.2 instruction: convertion from fix to retractable landing gear ......9.3 instruction: convertion from retractable to fix landing gear ......9.5 drawing FW 25: front landing gear lock ............9.7 Installation sketch EFWK ..................

  • Page 9: Airworthiness Limitations

    0.4.1 Repairs Repair or replace damaged parts prior to next flight. Follow the instructions of the DG-300 repair manual for repairs of the airframe. Repairs outside the scope of the DG-300 repair manual and major repairs must be accomplished at an approved repair station or by an approved mechanic rated for composite aircraft structure work in accordance with DG repair methods.

  • Page 10: System Description And Adjustment Data

    Maintenance Manual DG-300 System description and adjustment data 1.1 Wing and tailplane setting data Wing Sweep Back (leading edge): 0 at wing tip (tolerance ± 5 mm, ± 0,2 inch) Dihederal (leading edge line): 3° = 377 mm at the tip (14,84 inch)

  • Page 11: Elevator Deflections And Adjustment

    Maintenance Manual DG-300 1.2 Elevator deflections and adjustment 1.2.1 Control circuit see diagram 1 1.2.2 Elevator deflections and tollerance: 63 ± 1 mm 2,48 ± 0,04 inch Down 36 ± 1 mm 1,42 ± 0,04 inch measured 150 mm (5,9 inch) from hinge axis.
  • Page 12 Maintenance Manual DG-300 1.2.5 Trim: The automatic trim mechanism should be adjusted so that with full forward (nose down) trim, the control column is from 1 to 1,5 cm (0,4 – 0,6 inch) away from its maximum forward position. The tensioning of the trim mechanism springs is to adjust as shown on the sketch.

  • Page 13: Rudder

    Maintenance Manual DG-300 1.3 Rudder 1.3.1 Rudder Control circuit see diagram 2 1.3.2 Rudder deflections and tollerance: ± 215 ± 5 mm (± 30°) (8,46 ± 0,2 inch) measured at 414 mm (16,3 inch) from the hinge axis. 1.3.3 Rudder stops The rudder Stopps are located at the lower hinge point and can be adjusted with a 10 mm open end spanner.

  • Page 14: Aileron Control

    Maintenance Manual DG-300 1.4 Aileron control 1.4.1 Control circuit see diagram 3 1.4.2 Aileron deflections and tolerances 62 ± 3 mm (2,44 ± 0,12 in.) down 31 ± 3 mm (1,22 ± 0,12 in.) measured at 120 mm (4.72 in.) from hinge axis (at inboard end) 1.4.3 Aileron stops...

  • Page 15: Airbrake Control Circuit, Wheelbrake

    Maintenance Manual DG-300 1.5 Airbrake control circuit, wheelbrake 1.5.1 Control circuit see diagram 3 The wheelbrake cable is connected to the airbrake torsion shaft (part 3 St 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 –...

  • Page 16: Landing Gear

    Maintenance Manual DG-300 1.6 Landing gear retractable landing gear (for all Models) 1.6.1 Landing gear Control circuit see dDiagram 2 1.6.2 Adjustment a) Should the landing gear not retract fully, an adjustment can be made by screwing out the universal pushrod joint on pushrod No. FW 9a/3 with a 10 mm open end spanner.
  • Page 17 Maintenance Manual DG-300 Fix landing gear (only DG-300 Club ELAN and DG-300 Club ELAN ACRO)) 1.6.6 System see diagram 3 1.6.7 Convertion to retractable landing gear The convertion is possible, as the mounting bushes in the landing gear box are the same and the stands for the control circuit are already installed.

  • Page 18: Tow Hooks

    3 of this maintenance manual. 1.8 Water ballast system DG-300, DG-300 ELAN and DG-300 ELAN ACRO see diagram 5 DG-300 Club ELAN and DG-300 Club ELAN ACRO see diagram 6 a) Wing tanks 1.8.1 Water ballast release circuit see diagram 5 1.8.2 Adjustment...
  • Page 19 Maintenance Manual DG-300 1.8.3 Servicing see sect. 4.1 b) Fin tank DG-300, DG-300 ELAN und DG-300 ELAN ACRO 1.8.4 Fin tank adjustment The release cable must be adjusted so, that the wing tank handles only can be opened, when the fin tank has been opened fully.

  • Page 20: Massbalance And Weights Of Control Surfaces

    Maintenance Manual DG-300 1.9 Massbalance and weights of control surfaces After repairs or repainting the control surfacesweights and moments should not exceed the following limits: Control surface Weight Moment Spring balance reading when attached to the points described kg · cm (lbs) (lbs ·...

  • Page 21: Fore And Aft Play Of The Wings

    Maintenance Manual DG-300 1.10 Fore and aft play of the wings With the aircraft fully rigged move the wings fore and aft to determine at which shear pin the most play exists. Adjustment: Derig the gilder roughen the area around the shear pin and glue a washer inside Ø...

  • Page 22: Inspections

    Maintenance Manual DG-300 Inspections 2.1 Daily inspection see flight manual sect. 4.1. 2.2 Regularly inspections A) After 200 flighthours and during the yearly inspection: Check rudder cables for wear especially around the S tubes on the rudder pedals. Worn rudder cables should be replaced - see sect. 4.2.

  • Page 23: Inspection After A Heavy Landing

    Maintenance Manual DG-300 2.3 Inspection 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...
  • Page 24 Maintenance Manual DG-300 To check the elevator control circuit and the bulkhead attachments in the fin area, the tailwheel should be removed and a hole cut into the tailwheel housing as shown in the sketch. After completing the checks, the hole should be glassed over using 3 layers of 92 125 glass cloth.

  • Page 25: Inspection Procedure For Increase Of Service Time

    Maintenance Manual DG-300 2.4 Inspection procedure for increase of service time 1. General The results of fatigue tests of wingspar sections have demonstrated that the service time of GFRP/CFRP gliders and motorgliders may be limited to 12000 hours, if for each individual glider (in addition to the obligatory annual inspections) the airworthiness is demonstrated according to a special multi-step inspection program particularly with regard to the service life.

  • Page 26: Maintenance

    Maintenance Manual DG-300 Maintenance 3.1 General maintenance (see flight manual section 5.7) Exterior surfaces of the fibrereinforced plastic parts The surfaces are coated by a UP-gelcoat. This gelcoat is protected by a hard wax coating which has been applied during production with a rotating disc ("Schwabbel"...

  • Page 27: Maintenance Of The Airframe

    After a landing in a soft field, the landing gear box and tow hook should be thoroughly cleaned. 3.3 Greasing and oiling Every year your DG-300 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: - Aileron drive connection at the aileron.

  • Page 28: Damage Of The Airframe

    Minor damage such as small cracks and holes in the skin surfaces can be repaired by a licensed workshop. Additional information like a listing of all materials used in the DG-300 can be found in the repair manual. Home repairs should not be attempted when:...

  • Page 29: Detailed Instructions For Assembly And Servicing Work

    Maintenance Manual DG-300 Detailed instructions for assembly and servicing work 4.1 Replacement of the water ballast bags Unscrew the attaching bolt attaching the lines to the root rib and attach an additional 5 m (16.5 ft.) long line dia. 3 mm (.12 in.) to each Nylon cord.

  • Page 30: Adjustment Work On The Control Circuit

    Maintenance Manual DG-300 4.3 Adjustment work on the control circuit a. In all cases, new self locking nuts DIN 985.8 should be used. b. Bolts which are not secured with locking nuts have to be secured with Loctite 243. Before installing the bolt clean the thread and the inside thread with Acetone.

  • Page 31: Removal And Installation Of The Fix Landing Gear

    Diagram 2. 5. Reverse the above procedures to reinstall. 4.5 Removal and installation of the fix landing gear Only DG-300 Club ELAN and DG-300 Club ELAN ACRO A. Removal 1. Remove the wheel axis see diagram 3. 2. Remove the wheel brake cable at the brake lever by loosening the attachment screw.

  • Page 32: Removal And Reinstallation Of The Ailerons

    Maintenance Manual DG-300 4.6 Removal and reinstallation of the ailerons Only DG-300, DG-300 ELAN and DG-300 ELAN ACRO A. Removal 0. Remove the glasfibre cover plate from the wing-shell at the outboard end of the aileron cutout using a knife or a chisel.
  • Page 33 Maintenance Manual DG-300 10. Displace the aileron fully downward and fix it in this position. Remove the tape which fixes the teflonsealing to the wing surface and push the teflonsealing into the gap inbetween wing and aileron until its end corresponds with the film tape on the upper aileron surface.
  • Page 34 Maintenance Manual DG-300 Only DG-300 Club ELAN and DG-300 Club ELAN ACRO: A. Removal 1. Remove the glasfibre cover plate from the wingshell at the outboard end of the aileron cutout using a knife or a chisel. 2. Tear off the tape from the wing lower surface.

  • Page 35: Increasing The Aileron Massbalancing

    Maintenance Manual DG-300 4.7 Increasing the aileron massbalancing If the massbalance is out of limits after a repair the massbalancing may be increased as follows: 1. Place the disassembled aileron lower surface up. 2. There are tubes installed in the aileron nose inbetween the aileron hinges.

  • Page 36: Fixing Excessive Free Play Of The Canopy

    Maintenance Manual DG-300 4.8 Fixing excessive free play of the canopy Shrinkage of the fibre reinforced plastic material may result in free play between the canopy hinge R 48 and the canopy. You can fix the free play as follows: a) Take off the canopy and remove the emergency release spring.

  • Page 37: Centre Of Gravity Measurements-Weighing

    Maintenance Manual DG-300 Centre of Gravity measurements-weighing Method of weighing your DG-300: 1. Assemble the glider completely with gear down. 2. Place a scale under the tailwhell. 3. The fuselage must be leveled so that the top of the aft fuselage boom has a tail-down slope of l00 : 3.67.
  • Page 38 Maintenance Manual DG-300 Leveling line: Datum (d): Aft fuselage boom slope Wing leading edge near root 100 : 3,67 (tail down) ≥ 549 mm (21.6 inches) Pilot C.G. at WP = 70 kg 140 mm (5.5 inches) baggage C.G. 160 mm (6.3 inches) water...

  • Page 39: Instrument- Und Equipment List

    The airspeed indictor must have colour coded speed ranges marked as indicated in the flight manual section 2.3. Caution: As long as the DG-300 is operated with the reduced operation limitations according to TN 359/24 the colour marking must be modified. The last 3 digits of the ASI Ident No.

  • Page 40: Compass (As Min. Equipment Only Necessary For Cloud Flying)

    Maintenance Manual DG-300 6.4 Compass (as min. equipment only necessary for cloud flying) 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 Type 1...

  • Page 41: Outside Air Temperature Gauge

    TF 00-059 K (-20 - + 40 °C) 6.9 Beschleunigungsmesser As min. equipment only for DG-300 ELAN ACRO and DG-300Club ELAN ACRO for Category A Aerobatics Accelerometer capable of retaining max. and min. g-values with markings red radial lines at +7g and -5g.

  • Page 42: Liste Der Spezialwerkzeuge

    Spring balance: max. reading 50 N, 11 lbs. Nicopress tool 64 - CGMP only DG-300 with fin ballast tank (version with measuring stick): 1/4 inch extension piece 150 mm (6 inch) long with handle for the tank filler cap (supplied with the glider).

  • Page 43: Diagrams

    Maintenance Manual DG-300 Diagrams Diagram 1 Elevator control circuit, adjustment Issued: December 2009...

  • Page 44: Diagram 2 Rudder Control Circuit, Retractable Landing Gear

    Maintenance Manual DG-300 Diagram 2 Rudder control circuit, retractable landing gear Issued: December 2009...

  • Page 45: Diagram 3 Fix Landing Gear

    Maintenance Manual DG-300 Diagram 3 Fix landing gear DG-300 Club ELAN (ACRO) Issued: December 2009...

  • Page 46: Diagram 4 Aileron And Spoilers Control Circuits, Wheel Brake

    Maintenance Manual DG-300 Diagram 4 Aileron and spoilers control circuits, wheel brake Issued: December 2009...

  • Page 47: Diagram 5 Tow Hook, Water Ballast Release Systems Dg-300, Dg-300 Elan, Dg-300 Elan Acro

    Maintenance Manual DG-300 Diagram 5 Tow hook, water ballast release systems DG-300, DG-300 ELAN, DG-300 ELAN ACRO Issued: December 2009...

  • Page 48: Diagram 6 Tow Hook, Water Ballast Release Systems Dg-300 Club Elan, Dg- 300 Club Elan Acro

    Maintenance Manual DG-300 Diagram 6 Tow hook, water ballast release systems DG-300 Club ELAN, DG- 300 Club ELAN ACRO Diagram 4 Issued: December 2009...

  • Page 49: Diagram 7 Empty Weight Centre Of Gravity Range

    Maintenance Manual DG-300 Diagram 7 Empty weight centre of gravity range Approved empty weight C.G. range Issued: December 2009...

  • Page 50: Diagram 8 Placards Dg-300 & Dg-300 Elan

    Maintenance Manual DG-300 Diagram 8 Placards DG-300 & DG-300 ELAN Caution: Placards 12 and 15 are only applicable if TN359/24 instruction B is applicable, otherwise see diagram 12. Issued: August 2020 TN DG-SS-05...

  • Page 51: Diagram 9 Placards Dg-300 Elan Acro

    Maintenance Manual DG-300 Diagram 9 Placards DG-300 ELAN ACRO Caution: Placards 12 and 15 are only applicable if TN359/24 instruction B is applicable, otherwise see diagram 12. Issued: August 2020 TN DG-SS-05...

  • Page 52: Diagram 10 Placards Dg-300 Club Elan

    Maintenance Manual DG-300 Diagram 10 Placards DG-300 Club ELAN Caution: Placards 12 and 15 are only applicable if TN359/24 instruction B is applicable, otherwise see diagram 12. Issued: August 2020 TN DG-SS-05 8.10...

  • Page 53: Diagram 11 Placards Dg-300 Club Elan Acro

    Maintenance Manual DG-300 Diagram 11 Placards DG-300 Club ELAN ACRO Caution: Placards 12 and 15 are only applicable if TN359/24 instruction B is applicable, otherwise see diagram 12 Issued: August 2020 TN DG-SS-05 8.11...
  • Page 54 Maintenance Manual DG-300 Diagram 12 Placards 12 and 15 for DG-300 all variants if TN359/4 instruction A (reduction of operating limitations) is applicable. Issued: August 2020 TN DG-SS-05 8.12...

  • Page 55: Enclosures Installation Sketch Efk

    Maintenance Manual DG-300 Enclosures Installation sketch EFK Issued: December 2009...

  • Page 56: Installation Sketch 3 Ed

    Maintenance Manual DG-300 Installation sketch 3 ED Issued: December 2009...

  • Page 57: Instruction: Convertion From Fix To Retractable Landing Gear

    Maintenance Manual DG-300 Instruction: convertion from fix to retractable landing gear You need a convertion kit "retractable landing gear" containing the following parts: FW 21/1 front fork FW 21/2 rear lower fork FW 21/3 rear upper fork FW 7 rear upper half axis...
  • Page 58 Maintenance Manual DG-300 Instruction Execution: see also diagram 2 and section 4.4 1. Remove the wheel fairing 2. Remove the mainwheel and the wheel brake cable 3. Remove the fix landing gear 4. Install the retractable landing gear inside the wheel box 5.

  • Page 59: Instruction: Convertion From Retractable To Fix Landing Gear

    Maintenance Manual DG-300 Instruction: convertion from retractable to fix landing gear You need a convertion kit "fix landing gear" containing the following parts: FW 7 rear half axis FW 16/1 front strut FW 16/2 rear strut FW 17 front half axis...
  • Page 60 Maintenance Manual DG-300 Instruction Convertion from retractable to fix landing gear 1. Remove the landing gear doors see installation sketch EFWK. 2. Remove the main wheel see diagram 2 and disconnect the wheel brake cable at the front strut and at the main wheel.

  • Page 61: Drawing Fw 25: Front Landing Gear Lock

    Maintenance Manual DG-300 drawing FW 25: front landing gear lock Issued: December 2009...

  • Page 62: Installation Sketch Efwk

    Maintenance Manual DG-300 Installation sketch EFWK Issued: December 2009...
  • Page 63 Maintenance Manual DG-300 Issued: August 2020 TM DG-SS-05...
  • Page 64 Maintenance Manual DG-300 Issued: August 2020 TM DG-SS-05 9.10...
  • Page 65 Maintenance Manual DG-300 Issued: August 2020 TM DG-SS-05 9.11...
  • Page 66 Maintenance Manual DG-300 Issued: August 2020 TM DG-SS-05 9.12...

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