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DG Flugzeugbau DG-400 Maintenance Manual

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Maintenance Manual DG-400
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 and in the parts lists in section 8.
Yours sincerely
DG 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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Summary of Contents for DG Flugzeugbau DG-400

  • Page 1 8. Yours sincerely DG FLUGZEUGBAU GMBH Dipl.- Ing. W. Dirks Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 2 3.3, 3.6, 3.7, 8.2, TN DG-SS-02 diagram 8, delete diagram 8a 0.1, 0.5, 8.3 Rectifier-Regulator October 2017 TN DG-SS-03 Issued: October 2017 TN DG-SS-03 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 3 Maintenance Manual DG-400 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 " 1.19 " 1.20 " 1.21 " 1.22 " 1.23 " 1.24 " 1.25 " 1.26 1.27 Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 5 " 4.18 " 4.19 " 4.20 " 4.21 " 4.22 " 4.23 " 4.24 " 4.25 " Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 6 " December 09 " " December 09 December 09 " October 2016 " October 2017 8.4 " Issued: October 2017 TN DG-SS-03 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 7 June 1986 12 Installation brake motor (Option Sept BEA) 1990 13 Electrical system with Option Sept 1990 Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 8 432372501 Service Info 63/07 with working 28.03.07 instruction No. 1 for TN826/22 and drawing 4M81 28.03.07 Issued: December 09 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 9: Table Of Contents

    Regular inspections .................. 2.1 Inspections after a heavy landing............. 2.3 Inspection procedure for increase of service time ........2.6 Issued: December 09 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 10 4.19 Instructions for the removal and refitting of magneto flywheel ass'y and exchange of starter gear ................. 4.23 Weight and Balance ................. 5.1 Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 11 Electrical system Empty weight centre of gravity range Placards Installation brake motor (Option BEA) Electrical system with Option BEA Issued: December 09 0.10 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 12 Service Info 63/07 starter motor for Rotax 505 with working instruction No. 1 for TN826/22 and drawing 4M81 Issued: December 09 0.11 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 13: Airworthiness Limitations

    0.4.1 Repairs: Repair or replace damaged parts prior to next flight. Follow the instructions of the DG-400 repair manual for repairs of the airframe. Repairs outside the scope of DG-400repair 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 14: Service Time, Maintenance Documents Of Equipment And Components

    MT-Propeller Operation and installation manual No. E-203 latest approved version. 0.4.5 Power plant trouble shooting Please find a checklist in the DG-400 flight manual section 6.12.. Issued: December 09 0.13 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited...

  • Page 15: System Description And Adjustment Data

    Maintenance Manual DG-400 System description and adjustment data General description The DG-400 is a single place selflaunching high performance sailplane with retractable power plant. 15 m wing span with insertable wing tips for 17 m wing span. Further details see flight manual 1.2...

  • Page 16: Elevator Deflections And Adjustment

    (3mm = .12 in.) Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 17 Note: if the cable passes outside the mechanism control column movement could be blocked Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 18: Rudder

    Flexodicht Band 2743 white) which is attached within the fin spar space. This seal is not to be removed. If damaged it should be replaced and sprayed with Teflon. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 19: Aileron And Flap Control Circuits

    +12° 30 mm ± 3mm (1.18 ± . 12 inch) 0° 0mm Measured 145 mm (5.71 inch) from hinge axis. The displacements are not adjustable. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 20: Complete Readjustment

    In the event that the limit is exceeded, the pin in the ball on the flap itself should be replaced with an oversized one. (Part No.2St14/3). Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 21: Airbrake Control Circuit, Wheel Brake

    Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 22: Landing Gear

    If the tail wheel does not run free this may be caused by swelling of the hub and you have to take off material from the hub accordingly. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 23: Tow Hook

    8 mm (.32 in.) PVC rod should be loosened, pressed further in, and tightened again Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 24: Power Plant

    Additional note: On the ignition boxes the no. is given without the first digit = 32372501 instead of 432372501 as given in TN and working instruction. 1.10.3 Exhaust Muffler: The muffler has been specially designed for the DG-400 by Rotax, and is attached by three Rotax spring couplings secured with Loctite 243. 1.10.4 Propeller:...

  • Page 25: Propeller Positioning

    The brake force must be adjusted for a control force of 1.5 - 5 daN (3 - 11 lbs.). Issued: December 2009 1.11 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 26: Propeller Brake

    5 mm (.2 in) of pad left. The pad has to be glued on with metal adhesive. New replacement pads can be ordered through DG Flugzeugbau GmbH, or you can make them yourself from endless brake lining material (8mm, .32in thick).

  • Page 27: Retraction - Extension Mechanism

    Issued: December 2009 1.13 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 28: Fuel System

    Issued: December 2009 1.14 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 29: Fuel Quantity Indication

    When reassembling, use Loctite 243 to secure the screws of the cover. Issued: December 2009 1.15 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 30 (ca. 7/8 turns). Then turn out the tommy screw choke butterfly primer Issued: December 2009 1.16 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 31 Note: Also if the tanks remain in the wings they should not be emptied completely for longer storage periods. Issued: December 2009 1.17 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 32: Electrical System

    The engine time counter is connected directly to the generator and counts the pure engine running- time only. Type see section 8.2. Issued: December 2009 1.18 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 33: Electric Fuel Pump

    DC electric motor with a gearbox and electromagnetic brake Type – see section 8.1. The motor is provided with an antiinterference filter. Replacement filters Part No. 4E11 can be ordered through DG Flugzeugbau GmbH or their agents. Issued: December 2009 1.19...

  • Page 34: Safety Interlocks

    DEI is switched off. If this will no more work after some years of service, you have to ship the DEI in exchange to DG Flugzeugbau GmbH for replacement of the battery. Tachometer The tachometer is fully digital and counts the AC impulses from the generator.

  • Page 35: Connector Plug

    Connector plug at the engine mount: Type Amphenol C 1460. Connector plug at the DEI:- Type D Miniatur 25 Pole - MIL - C - 24308. Issued: December 2009 1.21 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 36 This is done by disconnecting the red cable marked with a black ring from the fuse terminal. See the sketch below. Issued: December 2009 1.22 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 37 Note: Do not charge for more than 1 week! Issued: December 2009 1.23 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 38: Massbalance And Weights Of Control Surfaces

    Hang the aileron friction free on its hinge points (pushrod disconnected) and attach the spring balance 100 rum (3.94 inch) (2nd hinge) behind the. hinge axis. Issued: December 2009 1.24 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 39: Fore And Aft Play Of The Wings And Outer Wings

    At the wing tip joint: The free play of the 2 pins together should not exceed 0.5 mm. Issued: December 2009 1.25 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 40: Option Bea Automatic Propeller Brake - Engine Retraction

    The extension relais will be operated by switching the ignition "on" or by operating the switch at the control stick Issued: December 2009 1.26 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 41 Type see sect.8.2 1.16.4 Limit switch (engine extended) at the engine mount. Type Hartmann 164-564 instead of the switch see sect. 1.13.9 c). This switch controls the BEA in addition to the standard DG-400 functions. 1.16.5 Fuse The BEA is protected via the 4 A fuse for the 12V socket see sect.

  • Page 42: Inspections

    Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 43 To check see sect. 3.4.1. No. 28. of this manual. C.G. weighing: After all work which may influence the C.G. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 44: Inspections After A Heavy Landing

    Remove gelcoat and any filler along the cracks, move the fin (push the fin towards the nose as well as applying torsion). Do the cracks penetrate the glass fibre structure? Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 45 Proper functioning and condition of all controls and adjustment mechanisms (ie rudder pedal adjustment, tow release, air brake and flap handles, control column and trim etc.) Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 46 Do all the engine compartnment doors still close properly? Proceed to do all the checks listed in section 2.1. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 47: Inspection Procedure For Increase Of Service Time

    5. The results of the inspections have to be recorded in an inspection test report wherein comments are required for each inspection instruction. If the inspections are done outside the DG Flugzeugbau facilities, a copy of the records must be sent to DG Flugzeugbau for evaluation and information.

  • Page 48: Maintenance

    Clean off remains of fuel and oil from the power plant and the engine compartment after every flying day. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 49: 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 Once a year your DG-400 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 root end of the aileron.

  • Page 50: Servicing The Engine

    For the check switch on the ignition to run the electric fuel pump to demonstrate operating fuel pressure. Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 51 Check all the hinges on the engine compartment doors for proper fit and any cracks, tears etc. Check if hinge pins are secured properly. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 52 Avionics only. This will switch off the electric fuel pump. No drop in engine RPM should be heard, otherwise the fuel system should be checked again. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 53: After 300 Engine Hours

    Caution: The new fuel lines must be flushed thoroughly with fuel after assembly. Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 54: When Required

    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-400 can be found in the repair manual. Home repairs should not be attempted when:...

  • Page 55: Instruction For Assembly And Servicing Work

    45 mm + 15 mm (1.77 + .6 in) above the engine block joint axis with the propeller in the vertical position. view from the front Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 56 By moving the aluminium magnetic switch mount sideways the centering of the allowable propeller position arc can be achieved. (Secure all mounting screws/bolts with Loctite 243). Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 57: Replacing The Bearings Of The Propeller Shaft

    9. Mount the propeller, tightening the propeller bolts 1.5 - 1.7 daN m (11 - 12 ft.lb.). Secure the propeller bolts with safety wire (stainless steel), see sect. 4.16. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 58: Removal And Disassembling Of The Spindle-Drive

    2. Reinstall the electrical connections of the spindle motor. Connect wire 75 to 751 and 76 to 761. Insulate with shrinking hose. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 59: Removal Of The Extension - Retraction Motor

    2. Unscrew the top and bottom gearbox plates. Remove the gearbox. 3. Grease the new gearbox inside with Molykote longlife grease. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 60: Replacement Of The Engine Extension Mechanism Gas Strut

    Loctite 243. Insert the bush into the lower attachment. Reverse the procedures for removal above. Use a new split pin. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 61: Installation And Removal Of The Engine

    6 mm dia. elastics for the forward engine doors. Secure the main electrical plug with lock wire. Insulate the CHT plug with shrinking hose. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 62 Maintenance Manual DG-400 4.6.3 Engine removal for flight without the engine installed When the DG-400 is to be flown without its engine, the following additional items should be done. Attach all cables and wires to the engine mounts using Ty-raps.
  • Page 63 The mounting screw should be secured with Loctite 243 and tightened with 5 daN m (37 ft lb). Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 64: Replacing The Water Ballast Tanks

    (see above). The front line should not be tensioned. Issued: December 2009 4.10 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 65: Replacement Of Wing Fuel Tanks

    Attach the wire for the electrostatic connection by use of a pop-rivet see sketch, if there is no plug installed. Issued: December 2009 4.11 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 66: Replacement Of Control Circuit Cables

    Caution: All lock nuts (B) are secured by a spring washer (C) DIN6798 I. Be careful not to loose that washer! Issued: December 2009 4.12 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 67: Removal And Installation Of The Landing Gear

    Tighten the adjusting bolts for 30 mm (1.18 in) clearance – see Diagram 2. Reverse the above procedures to reinstall Issued: December 2009 4.13 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 68: Access To Cylinderheadnuts

    Loctite 243 to secure all bolts. The 3 bolts M 8 x 16 (see 9.) have to be cleaned before. Issued: December 2009 4.14 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 69: Fixing Excessive Free Play Of The Canopy

    1.3 item 29. The opening force for the emergency release should in no case exceed 20 daN (44 lbs)! Issued: December 2009 4.15 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 70: Working Instructions For Heat-Shrink Tubing

    96A means January 1996, 96B means February 1996 and so on. Issued: December 2009 4.16 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 71: Instruction For Securing The Propeller Bolts

    Caution: Don't damage the lock wire. Also minor scratches or removal of the galvanization have to be considered as damage. Issued: December 2009 4.17 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 72: Checking The Ignition Unit

    After turning the armature plate fix the bolts and check the ignition timing again. Repeat this procedure until the timing is correct. Issued: December 2009 4.18 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 73 4.18 and 4.19. Check the coils for damage and replace if necessary. Centre and secure the coils see sect. 4.18 item 6. Issued: December 2009 4.19 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 74: Ignition Unit - Trouble Shooting

    Therefore remove the adhesive and secure again with metal adhesive (e.g. Uhu Plus) after soldering. Issued: December 2009 4.20 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 75 100 - 200 V must be there. Warning: Dangerous Voltage! Don't touch the plugs while the engine is running. Issued: December 2009 4.21 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 76 Distance sleeve 5.4/11/12 847 310 Distance ring 5.4/10/3 866 780 Armature support 940 801 bolt M5 x 40 DIN 931 Issued: December 2009 4.22 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 77: Instructions For The Removal And Refitting Of Magneto Flywheel Ass'y And Exchange Of Starter Gear

    22 A/F Advice: If need be, break bond of flywheel to crankshaft taper by carefully heating up to 120° Issued: December 2009 4.23 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 78 935 956 starter gear 77 Z 865 638 magneto housing 899 785 Loctite 221 899 788 Loctite 648 Issued: December 2009 4.24 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 79 3.5. Secure hex. nut M22 x 1,5 with Loctite 221, 899 785, tighten with 140 Nm. Allow three hours curing time for Loctite, prior to engine start. Issued: December 2009 4.25 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 80: Weight And Balance

    (barograph, camera, cushions, etc.). In addition, the rudder pedals and seat back should be adjusted as in flight. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 81 If the min. cockpit load has changed, the new value must be entered in the cockpit data placard. Weight and balance must be carried out at least every four years. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 82: Instrumentation And Accessories List

    40.071/21 Autoflug BAGU FAG-12 D-O 40.070/47 SCHUGU FAG-12 H-O 40.071/25 Schroth 4-01-0104 40.073/11 Schroth 4-01-0108 with Option NOAH 40.073/11 Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 83: Engine Instrumentation

    EASA.210.0193 or other instruments certified for aircraft use according to TSO or JTSO or ETSO standards may be installed. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 84: Variometer

    Electrical instruments and equipment must be connected via appropriately rated fuses, the power consumption of each single part should not exceed 3A. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 85: List Of Special Tools

    Special wrench for adjusting the idle stop at the Mikuni carburettors see drawing W 33 part 2. Special wrench for CHT Probe see drawing W 34. Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 86: Partlist

    Ball bearings for upper pulley 6009-2Z 39001024 Service kit nuts and bolts for 300 hour overhaul 60000174 Gas spring for engine door A1A1-90-71-225/120N Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 87 60500238 Intake funnel 60500239 Sealing 60500141 Air filter for Mikuni carburettors 60500242 Intake funnel 60500140 Air filter Issued: October 2016 TN DG-SS-02 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 88: Parts For The Electrical System

    10007070 Switch MST 106 D (switch Avionics + engine / Avionics) 60504024 Engine time counter Grässlin Typ EGZQ52 Issued: October 2017 TM DG-SS-03 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...
  • Page 89 60510801 Preh 71 206 2P (socket in baggage compartment) 60510800 plug Preh for socket in baggage compartment b) possible replacement: 60510796 socket BSB12 60510797 plug BSK12 Issued: December 2009 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited Manual valid with the up-to-date cover page only...

  • Page 91: Service Information

    SUBJECT Hotellier control quick connectors CONCERNING : DG-100 (G), DG-100 (G) ELAN DG-200, DG-200/17, DG-200/17C DG-400 all serial no.'s REASON The sliding latch of the quick connectors may loose its Nonreversibility due to lubricants. This is most impor- tant for the airbrake control hook up.

  • Page 107: Service Information

    SUBJECT Hotellier control quick connectors CONCERNING DG-100 (G), DG-100 (G) ELAN DG-200, DG-200/17, DG-200/17C DG-400 all serial no.'s REASON The sliding latch of the quick connectors may loose its Nonreversibility due to lubricants. This is most impor- tant for the airbrake control hook up.
  • Page 121 DG-200/17C:„DG-200/17C Manual“, page 1 „Maintenance manual DG-200/17C“, page 0, 7c DG-400: „Maintenance manual DG-400“, page 0.2, 1, 2, 2a, 26b Working instructions No.1 and No.2 for this TN For instruction 3: If necessary: 1 pcs. Sheet steel 1St12/2, material 1.7734.4 Welding wire material 1.7734.2...
  • Page 122 No. 301/18, 323/9, 826/34 D-76646 Bruchsal 4 Inspection and repair of the airbrakes (DG-100, DG-200, DG-400) 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 1-3mm (0.039-0.118in) above the wing surface (s. sketch 1).
  • Page 123 No. 301/18, 323/9, 826/34 D-76646 Bruchsal 4 Inspection and reinforcement of the airbrake torque tube (DG-100, DG-200, DG-400) Prior to the next flight the airbrake torque tube in the fuselage must be inspected. Check the welded joint to the operating lever on cracks or deformation when locking and unlocking the airbrakes on the rigged airplane. The airbrake torque tube can be reached through the inspection hole in the fuselage.
  • Page 124 : The existing motor is no more available. Thus a new design with a newer type of motor was necessary. This motor has different sizes. Instructions Remove the old motor: DG-400 according to maintenance manual section 4.4.1, DG800 according to maintenance manual section 4.14.1. Install the new motor according to drawing 4R14 issue e.
  • Page 126 No. 826/46 Subject : Power plant ignition system Effectivity : DG-400, all serial numbers Accomplishment : In case of defect of one ignition box or of the front spark plug connector (only with ignition system with Bosch Polarfire electronic boxes) Reason : 1.
  • Page 127 To execute this work the engine should be removed from the plate 4M7 and rotated 90° to the front. Please refer to sect. 4.12 of the DG-400 maintenance manual for this procedure. Protect the spindle drive against dirt. issued: August 23.2006...
  • Page 128 8. Check the ignition timing according to the maintenance manual sect. 4.16.1 9. Accomplish a test run with magneto check Tightening torques and securing methods: Please refer to maintenance manual DG-400 section 1.9.10 resp. 1.10.10 for MM from issue date December 2009 on.
  • Page 132 DG Flugzeugbau GmbH Working instruction No. 2 page 1 from 5 76646 Bruchsal to TN 826/46 Modification of the powerplant – ignition unit to Ducati 432372501 ignition electronic boxes A: Only in case the engine is equipped with Ducati 432372501 boxes: Remove the ignition electronic boxes, they will not be used again.
  • Page 133 DG Flugzeugbau GmbH Working instruction No. 2 page 2 from 5 76646 Bruchsal to TN 826/46 Picture 1 Picture 2 Warning: don’t mix up the wire colours! Issued: august 23.2006...
  • Page 134 DG Flugzeugbau GmbH Working instruction No. 2 page 3 from 5 76646 Bruchsal to TN 826/46 Picture 3 Picture 4 Issued: august 23.2006...
  • Page 135 DG Flugzeugbau GmbH Working instruction No. 2 page 4 from 5 76646 Bruchsal to TN 826/46 Picture 5 Sketch 1 Issued: august 23.2006...
  • Page 136 DG Flugzeugbau GmbH Working instruction No. 2 page 5 from 5 76646 Bruchsal to TN 826/46 Sketch 2 Issued: august 23.2006...
  • Page 138 1. Modify the flange of the new starter motor according to drawing 4M81. 2. Exchanging the starter motor: In DG-800 A or DG-400 with previous starter “Bosch American 992807” Exchange parts 4M5/1 and /2 against parts 4M5/3 and /4. Then carry out step 13 of working instruction 1 for TN 826/22.
  • Page 139 DG Flugzeugbau GmbH Service Info page 2 from 2 76646 Bruchsal No. 63-07 Bruchsal, date: March 28. 2007 Author: Peter Bruchmüller This service info has been approved by EASA date 23. April 2008 with technical note DG-G-04. Approval No. EASA.A.C.09568.
  • Page 145 SUBJECT Hotellier control quick connectors CONCERNING : DG-100 (G), DG-100 (G) ELAN DG-200, DG-200/17, DG-200/17C DG-400 all serial no.'s REASON The sliding latch of the quick connectors may loose its Nonreversibility due to lubricants. This is most impor- tant for the airbrake control hook up.

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