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.
Page 2: General
Maintenance Manual LS10-s, -st 0 General 0.1 Manual amendments No. Page Description Date 0.1, 0.3 ÷ 0.7, 0.13, 1.5, Manual revision December 1.19, 1.36, 2.1, 3.4, 4.1, TN LS10-02 2011 4.2, 4.17, 4.25, 6.2 ÷ 6.4, 7.1, 8.1, 9.3, 9.4, 9.6, diagrams 1, 3, 5,...
Page 3 Maintenance Manual LS10-s, -st This page was intentionally left blank. Issued: December 2011 TN LS10-02...
Page 4 Maintenance Manual LS10-s, -st 0.2 List of effective pages Section page issued replaced/ replaced/ replaced/ October 09 see manual amendments " " " " " " October 09 " 0.10 " 0.11 " 0.12 " 0.13 " December 11 0.14 "...
Page 5 Maintenance Manual LS10-s, -st List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ 1.26 " 1.27 " 1.28 " 1.29 " 1.30 " 1.31 " 1.32 " 1.33 " 1.34 " 1.35 " 1.36 " December 11 1.37 "...
Page 6 Maintenance Manual LS10-s, -st List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ October 09 4.10 " 4.11 " 4.12 " 4.13 " 4.14 " 4.15 " 4.16 " 4.17 " December 11 4.18 " 4.19 " 4.20 "...
Page 7: Table Of Contents
Maintenance Manual LS10-s, -st List of effective pages (continued) Section page issued replaced/ replaced/ replaced/ October 09 " October 09 " December 11 " December 11 " December 11 October 09 December 11 October 09 December 11 " 8.2 "...
Page 8 Maintenance Manual LS10-s, -st 0.2 List of effective pages (continued) diagram issued replaced/ replaced/ replaced/ September 09 December 11 September 09 September 09 December 11 September 09 September 09 December 11 September 09 September 09 September 09 September 09 September 09...
Page 9 Maintenance Manual LS10-s, -st 0.3 List of content page 0 General 0.1 Manual amendments ................0.1 0.2 List of effective pages ................0.3 0.3 List of content ..................0.8 0.4 Airworthiness limitations..............0.13 1 System description and adjustment data 1.1 Wing and tailplane setting data.............. 1.1 1.2 Elevator control and trim system ............
Page 10 Maintenance Manual LS10-s, -st 1.15 Power Plant (only LS10-st).............. 1.20 1.16 Retraction - Extension Mechanism (only LS10-st) ......1.24 1.17 Fuel system (only LS10-st).............. 1.27 1.18 Carburettor (only LS10-st)............... 1.30 1.19 Electrical system ................1.31 2 Inspections 2.1 Daily inspection ..................2.1 2.2 Regular inspections ................
Page 11 Maintenance Manual LS10-s, -st 4.7 Removal and installation of the flaperons ........... 4.16 4.8 Control surface seals and turbulators........... 4.18 4.9 Determination of the moments of the flaperons ........4.23 4.10 Permanent Installation of fixed Ballast at rear Fuselage ....4.25 4.11 Installation of the ballast holder in the fin ........
Page 12 Maintenance Manual LS10-s, -st 9 Enclosures 9.1 Equipment list ..................9.1 9.2 Checklist for checks and maintenance work (only LS10-st) ....9.2 9.3 Annual Inspection Checklist ..............9.3 9.4 Checklist engine removal and installation ..........9.7 Issued: December 2011 TN LS10-02...
Page 13: Diagrams 1
Fuel system up to ser. no. L10-014 Fuel system from ser. no. L10-015 on Enclosures Wiring plan LS10-st (DIN A3 in aircraft log) Wiring plan LS10-s (DIN A3 in aircraft log) 9EP22 Installation 406 MHz ELT antenna BD3 9EP24 Installation plan ELT or additional battery...
Page 14: Airworthiness Limitations
Repair or replace damaged parts prior to next flight. Follow the instructions of the LS10-S,-ST repair manual for repairs of the airframe. Repairs outside the scope of LS10-s,-st repair manual and major repairs must be accomplished at a certified repair station or by an approved mechanic rated for composite aircraft structure work in accordance with DG repair methods.
Page 15: October
Maintenance Manual LS10-s, -st 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 Date of Issue: February 1989 And if installed: Operating Manual for Tow Releases...
Page 16: System Description And Adjustment Data
Maintenance Manual LS10-s, -st 1 System description and adjustment data 1.1 Wing and tailplane setting data Wing: Sweep back (Leading edge): 13 + 3 mm (0.51 + 0.12 in.) at wing taper change (y=3.3 m) Dihedral (Leading edge line): 3° = 158 mm (6.24 in.) at wing taper change (y = 3.3 m)
Page 17: Elevator Control And Trim System
Maintenance Manual LS10-s, -st 1.2 Elevator control and trim system 1.2.1 Control system see diagram 1 1.2.2 Elevator deflections and tolerances 35 + 1 mm 1.38 + 0.04 in. down: 30 + 1 mm 1.18 + 0.04 in. to be measured at 70 mm (2.76 in.) from hinge axis which is at the outboard end of the elevator.
Page 18: Rudder Control
Maintenance Manual LS10-s, -st 1.3 Rudder control 1.3.1 Rudder control circuit see diagram 2 1.3.2 Rudder deflections and tolerances 197mm (7.76 inch) (29°) +5mm (-.2 inch) measured at 394 mm (15.5 inch) from the hinge axis. This is at the lower end of the rudder.
Page 19 Maintenance Manual LS10-s, -st upper rudder hinge 1.3.5 Sealing the rudder The rudder is sealed on both sides. On the outside with Mylar tape and inside the fin with V-sealing tapes These sealings are not to be removed. If damaged it should be replaced, see section 4.8.3...
Page 20: Aileron And Wing Flap Control
Maintenance Manual LS10-s, -st 1.4 Aileron and wing flap control 1.4.1 Control circuit see diagrams 3 and 4 2 springs (9St08) at the aileron control rod 4R10-73 provide additional aileron return forces to improve flight handling qualities especially at positive wing flap settings.
Page 21: October
Maintenance Manual LS10-s, -st 1.4.5 Complete readjustment Should it be necessary to completely reset the flap and aileron control, proceed as follows: Preparations 1. Derig the glider. 2. Remove the fairings from the wings and from the control surface horns. Then unscrew the horns (Allen key wrench) and loosen the lock nuts at the rod ends (Adjustment is made by rotating the complete drive).
Page 22 Maintenance Manual LS10-s, -st Basic adjustment wingflap control 10. Assemble the wings to the fuselage, fix the control stick in its vertical position. Set the wing flap handle to flap setting -1 (-4°). 11. If the flaperons have different displacements on left and right hand side adjust at pushrod 4R10-175 which is connected directly to the control stick 2R03-049.
Page 23: Airbrake Control, Wheelbrake
Maintenance Manual LS10-s, -st 1.5 Airbrake control, wheelbrake 1.5.1 Control circuit see diagrams 5 and 6. The wheelbrake cable is connected to the airbrake torsion shaft (part 9St13). 1.5.2 Adjustment a) The airbrakes must retract at their outboard ends 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 24 Maintenance Manual LS10-s, -st 1.5.4 Free play Free play in the airbrake control system is not detrimental. The airbrakes themselves at their hinges should not have so much free play that they hit the wing surface instead of entering into their boxes during retraction under airloads.
Page 25: Undercarriage
Maintenance Manual LS10-s, -st 1.6 Undercarriage 1.6.1 Main undercarriage 1.6.1.1 Undercarriage control circuit see diagram 7, undercarriage see diagram 1.6.1.2 Adjustment a) Extended Landing gear locking with wheel extended, see sketch below. Length of pushrods 4R2-90 and 4R2-112 must be adjusted so that landing gear handle 4R2-87 can be locked into rear guide detent only by using force.
Page 26 Maintenance Manual LS10-s, -st 1.6.1.3 Free play Play between outer drive 1R2-84 and inner drive 3R2-202 occurs as a result of overload and is not permitted. Deformations in this region can only be verified with items 1R2-84 and 3R2-202 taken out and cannot be compensated by adjustments.
Page 27: Tow Hooks
Maintenance Manual LS10-s, -st 1.7 Tow hooks 1.7.1 Tow release circuit see diagram 9 1.7.2 Adjustment With the tow release handle fully pulled, both hooks must definitely be fully open. With the handle loose, both hooks must be completely closed.
Page 28: Water Ballast System
1.8.2 Detailed description of the systems The LS10-s, -st waterballast system consists of 2 independent systems. System 1 consists of the outer and centre wing tanks (approx. 83 kg / 183 lbs total) and a fin tank (left hand dump valve) (3,9 kg / 8,6 lbs). All tanks of system No.1 are controlled via the forward water ballast control handle...
Page 29 Maintenance Manual LS10-s, -st System 2 consists of the inner wing tank (approx. 106 kg / 234 lbs total) and a fin tank (right hand side outlet) (4.6 kg / 10.1 lbs). All tanks of system 2 are controlled via the rear water ballast control handle installed on the RH side of the cockpit.
Page 30 Maintenance Manual LS10-s, -st 1.8.5 Dump times: After any adjustment work on the waterballast system the dump times must be checked.. The dump times of the fin tanks should be checked at every annual inspection. The following values shouldn’t be exceeded:...
Page 31: Massbalance And Weights Of Control Surfaces
Maintenance Manual LS10-s, -st 1.9 Massbalance and weights of control surfaces After repairs or repainting the control surfaces weights and moments should not exceed the following limits. Surface Mass Moment spring balance reading see instructions below kg cm kg cm (lbs.) (lbs.) (lbs.in.) (lbs.in.) (lbs.)
Page 32: Fore And Aft Play Of The Wings
Maintenance Manual LS10-s, -st 1.10 Fore and aft play of the wings 1.10.1 At the fuselage a) With the aircraft fully rigged, move the wings fore and aft to determine at which lift pin the most play exists. b) Derig the glider.
Page 33: Static And Pitot System
Maintenance Manual LS10-s, -st 1.11 Static and pitot system 1.11.1 System description See diagram 12 1.11.2 servicing No special service necessary but check static sources for cleanliness regularly. 1.12 Drain holes Issued: October 2009 1.18...
Page 34: Cockpit Canopy
Maintenance Manual LS10-s, -st 1.13 Cockpit canopy 1.13.1 Canopy locking and emergency release function: Measure force required to open canopy emergency release according to following steps (If this measurement or an operational check is performed without a helper, the spring for the canopy emergency jettison LS hook (Röger hook) at the rear upper end of the canopy becomes deformed and...
Page 35: Power Plant (Only Ls10-St)
Maintenance Manual LS10-s, -st 1.15 Power Plant (only LS10-st) 1.15.1 Arrangement: see diagrams 14 - 17. You will find a part list with the designations and the reference numbers for the powerplant parts in section 8 of this manual. 1.15.2 Engine: Air-cooled engine Type SOLO 2350 with electronic single magneto ignition.
Page 36 Maintenance Manual LS10-s, -st Note: Two bolt heads of the propeller mounting act as signal provider for the proximity switch (RPM measurement). These bolts have additional shims under the bolt heads. When re-fitting a propeller mount, make sure not to forget those shims or to fit them in other places! See also section 1.19.13.
Page 37 Maintenance Manual LS10-s, -st Propeller stopper gas strut inspection: Retract engine so that stopper is fully at stop, turn propeller away from stop arm. Force required to move stopper rubber perpendicular to its front plane to the rear between 20 and 25 N <4.5 to 5.6 lbs>.
Page 38 Maintenance Manual LS10-s, -st 1.15.8 Tightening torques and locking: For all screwed joints at the engine, the following torque values from the engine manufacturer are valid: Item ft*lbs Ignition plug 2.04 14.75 Decompression valves 2.04 14.75 Hub (on crankshaft) M12 x 1 left-hand 5.10...
Page 39: Retraction - Extension Mechanism (Only Ls10-St)
Maintenance Manual LS10-s, -st 1.16 Retraction - Extension Mechanism (only LS10-st) 1.16.1 Layout see diagram 18 – 20 and 16 1.16.2 The retraction-extension mechanism The electromechanically controlled extension-retraction system consists of a sealed electromechanical lift cylinder with a trapezoidal spindle and 12 V motor.
Page 40 Maintenance Manual LS10-s, -st 1.16.4 Adjustment of engine position fully extended, retaining cable and cable stops Fully extended position is defined by gas strut position. a) Extend limit switch adjustment by positioning cam block on switching rod. With the the limit switch operating, the distance between gas strut rod end bracket and gas strut housing must be 212 ±...
Page 41 Maintenance Manual LS10-s, -st 1.16.5 Position switches a) Limit position switches 1. Retraction limit switch: Switch at left side in engine bay, operated by inlet manifold (see diagram 14, item 18). Retraction limit switch operates when rear crankcase rests on plastic stop block on engine bay floor.
Page 42: Fuel System (Only Ls10-St)
Maintenance Manual LS10-s, -st 1.17 Fuel system (only LS10-st) 1.17.1 Layout see diagram 22 up to ser. no.. L10-014 and 23 from ser. no.. L10-015 1.17.2 Tanks Main tank and feeder tank together form the fuel tank. Fuel outlet in feeder tank via finger filter.
Page 43 Maintenance Manual LS10-s, -st 1.17.3 Fuel pumps Electrical fuel pump: The electrical fuel pump is mounted at the rear side of the feeder tank. Electrical supply from the electrical system, controlled by the DEI-NT. When the DEI-NT fuel pump switch is in “AUTO” position (normal operation) the pump is controlled by the automatic engine operation system and the electrical supply comes via the DEI-NT.
Page 44 Maintenance Manual LS10-s, -st Re-fuelling pump: The electrical refuelling pump is also fixed at the rear side of the feeder tank and is the only means for refuelling. Electrical supply is via the electrical system, controlled by DEI-NT. Push button for actuation located in the instrument panel. The filling line with fuel-tight quick connector is located in the baggage compartment.
Page 45: Carburettor (Only Ls10-St)
Maintenance Manual LS10-s, -st 1.18 Carburettor (only LS10-st) 1.18.1 Type: 2 carburettors without throttle control Fuel/Air mixture control: The fuel delivery to the engine is controlled by a jet each and was optimized by the manufacturer. Changes or corrections of jets should be approved by the manufacturer.
Page 46: Electrical System
In addition the plugs from the wiring leading to control unit or DEI-NT shall be sealed with tape when they are removed from the control unit or from the DEI-NT. 1.19.1 Layout see wiring plans drawings 9E4 (LS10-s) and 9E2 (LS10-st) enclosed to this manual. 1.19.2 Batteries •...
Page 47 To charge the batteries to their max. capacity such a charger with a max. output voltage of 14.4 V is required (most chargers supply only 13.8 V). A suitable charger Z 08 is supplied by DG Flugzeugbau. Note: Don't charge longer than for 1 week.
Page 48 Maintenance Manual LS10-s, -st 1.19.5 Wiring The wire gauges are given in the wiring plan 9E002 (LS10-st) and 9E004 (LS10-s) at the end of the wire No. in mm² or in AWG. Shielded wires may be identified by circles at their ends. Specification mm²...
Page 49 Maintenance Manual LS10-s, -st 2. Only LS10-st: For the following circuits self resetting fuses are incorporated in the DEI-NT: a) Fuel pump („AUTO“-Mode) (4A) b) Re-fuelling pump (4A) c) Proximity switch (0,2A) 3. Only LS10-st: For the following circuits self resetting fuses are...
Page 50 Maintenance Manual LS10-s, -st 1.19.10 Power plant extension-retraction mechanism (only LS10-st) See also sect. 1.16 The automatic extension and retraction is controlled by the control unit (see sect. 1.19.7) The extension-retraction motor will be switched off at the end limits by position switches (see sect.
Page 51: December
Maintenance Manual LS10-s, -st 1.19.13 Proximity switch (only LS10-st) The inductive proximity switch at the engine gets pulses from two bolt heads on the back of the propeller flange, see diagram 15. It switches the following functions: 1. Activation of the retraction mechanism and indication in the DEI- 2.
Page 52: October
Maintenance Manual LS10-s, -st 1.19.14 refuelling pump system (only LS10-st) Start the pump by pressing the push button located at the instrument panel. Ignition must be switched “OFF”. Electrical supply for the re- fuelling pump is via the onboard electrical system, control via DEI-NT.
Page 53 DEI-NT housing. 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. Issued: October 2009...
Page 54: Inspections
Maintenance Manual LS10-s, -st 2 Inspections 2.1 Daily inspection see flight manual section 4.3 2.2 Regular inspections 2.2.1 After 200 flight hours and during the annual inspection Check the rudder cables for wear especially around the S tubes on the rudder pedals.
Page 55: October
Maintenance Manual LS10-s, -st 2.2.3 Every 3 months Check the emergency canopy release according to flight manual sect. 7.16. 2.2.4 Casual inspections Tow hook After out landings in high grass or on soft ground, check C.G. hook for contamination or damage.
Page 56: Inspections After A Heavy Landing
Maintenance Manual LS10-s, -st 2.3 Inspections after a heavy landing The whole aircraft Check that the tailplane is still properly aligned in the vertical and horizontal axis. Check the wing oscillating frequency with respect to previous checks. Wings Check the wing pins and bushes for any deformation - are there any white...
Page 57 Maintenance Manual LS10-s, -st 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...
Page 58 Maintenance Manual LS10-s, -st Engine compartment: Check for damage of the walls. Does the engine retract without scratching the side walls? Do the engine doors fit as well as before? Check the condition of the fire resistant paint. Check spindle drive for unsusual noise during operation.
Page 59: 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 60: 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 61: Maintenance Of The Airframe
Maintenance Manual LS10-s, -st 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 62: Greasing And Oiling
Maintenance Manual LS10-s, -st 3.3 Greasing and oiling Once a year your glider should be carefully checked and all bearings, including control surface hinges, should be cleaned and greased if necessary. The various greasing points are as follows: • Flaperon drive connections at the flaperon.
Page 63: December
Maintenance Manual LS10-s, -st Note: The following sliding guides are maintenance-free and must not be greased. But in case of excessive friction you may proceed as follows: Remove the pushrod and clean pushrod and guide. If there is still too much friction you may apply a small amount of Molykote grease BR2 (-30°- 130°C <-...
Page 64: Damage Of The Airframe
With major damage, contact DG Flugzeugbau factory immediately and send photographs and a damage report from a licensed inspector or from an appropriately rated mechanic. With this information, the correct repair procedures can then be determined.
Page 65: Servicing The Engine
Maintenance Manual LS10-s, -st 3.5 Servicing the Engine Caution: If you don't operate the engine for periods longer than 2 months you must preserve your engine according to the instructions in the engine manual. The same applies for any overseas transportation.
Page 66 Maintenance Manual LS10-s, -st Exchange fuel filters of fuel supply and re-fuelling lines. Filter positions see diagrams 22 and 23, type of filter see parts list section 8. Check fuel lines for condition, chafing marks, tight fit and fuel tightness.
Page 67 Maintenance Manual LS10-s, -st Retaining cable Inspect retaining cable for wear and kinks. Inspect thimble, brass bushing and bolt of attachment to engine for wear. Check retaining cable adjustment, see section 1.16.4. Engine bay doors Check door hinges for tight fit and cracks and hinge bolting for tight fit.
Page 68 Maintenance Manual LS10-s, -st Fuel tanks Visual inspection of tanks for damage and leaks. Check fuel level sensors: - Empty tank as described under item 11 either using fuel pump or drain valve until reserve sensor switches and DEI-NT shows reserve level.
Page 69 Maintenance Manual LS10-s, -st 3.5.2 Every 5 years Every 5 years a special engine inspection is due, which may be performed by either the engine manufacturer, an appropriately certified repair shop or an appropriately certified maintenance technician. 3.5.3 After 200 engine hours After 200 engine hours an overhaul is due.
Page 70: Detailed Instructions For Assembly And Servicing Work
Maintenance Manual LS10-s, -st 4 Detailed instructions for assembly and servicing work 4.1 Seat shell removal and reinstallation 4.1.1 Removal (1) Remove battery cover from front seat end (2 Camlock fasteners). (2) Only LS10-st: Remove 4 bolts holding DEI-NT at seat front and pull out DEI-NT to the front (in direction of flight).
Page 71: Replacement Of Control Circuit Cables
Maintenance Manual LS10-s, -st (10) Place battery cover to front seat end and lock the 2 Camlock fasteners. (11) Check control system after installation for proper operation (12) Only LS10-st: Check the DEI-NT for proper functioning. 4.2 Replacement of control circuit cables Control cables and connections For processing Nicopress sleeves refer to FAA "Aircraft Inspection and Repair”...
Page 72: Adjustment And Servicing Of The Control Circuit
Maintenance Manual LS10-s, -st 4.3 Adjustment and servicing of the control circuit 1. Always use new self-locking nuts according to LN 9348 or DIN985-8zn. 2. All bolts, not secured by self-locking nuts, must be secured with Loctite 243. Before using bolt, clean off Loctite residue from both bolt and internal thread.
Page 73: Water-Ballast System
Maintenance Manual LS10-s, -st 4.4 Water-ballast system See diagrams 10 and 11, description see section 1.8. 4.4.1 Adjustment of the waterballast system Adjustment of wing-side and fuselage-side systems must be performed together. 1. Derig the glider. Remove baggage compartment floors and holder 9R96 with additional battery or ELT.
Page 74 Maintenance Manual LS10-s, -st Check fin tanksvalves for tightness, one after the other. Fill in approx. 1 Liter of water and rotate the waterballast handles to the forward (closed) position. Remove filling hose and check for tightness. If untight the spring see item 4 must be tensioned a little more, test again.
Page 75 Maintenance Manual LS10-s, -st 9. Adjust the waterballast levers 9R67 at the fuselage side root so that a min. travel of 20 mm >.79 in.> (see sketch) will be achieved. To accomplish this move the clamp 9R68. Adjustment dump valves closed 10.
Page 76 Maintenance Manual LS10-s, -st Adjustment dump valves open 13. Rotate both cockpit waterballast handles backward to the open position. 14. Measure the distance from fuselage lower side to the lowest edge of the valve cap. If this distance is not within the limits, the dump time may be different to the design values which may result in asymmetric ballast or in a C.G.
Page 77 Maintenance Manual LS10-s, -st If the opening distance of 1 valve is within and the other valve is outside the limits proceed as follows: 1.) Derig the wings and place them on stands, lower side up. 2.) Disassemble the valve cap 4F05-113 and the outer ring 4F05-112 from the centre valve (see section 4.4.2).
Page 78 Maintenance Manual LS10-s, -st 4.4.2 Removal and installation of a wing tank dump valve Removal 1. Drill a 4 mm (0.16 in.) hole into the centre of the plastic cap 4F05-141. 2. Insert a small screw drive into this hole and pull out the cap.
Page 79 Maintenance Manual LS10-s, -st 4.4.3 Fixing leaking wing tank dump valves With a leaking wing tank dump valve proceed as follows: 1. Rig the glider. 2. Rotate both waterballast handles in the cockpit forwards to the closed position. 3. Check if all dump valves close completely. If not readjust the control cables according to section 4.4.1.
Page 80 To accomplish this a major composite repair is necessary as the valve can’t be removed without cutting the fuselage shell. Ask the DG Flugzeugbau for a working instruction. Dump time (see section 1.8.5) too long With too long dump time of one or both fin tank valves first try to adjust the system according to section 4.4.1.
Page 81: Hook System Removal And Installation
Maintenance Manual LS10-s, -st 4.5 C.G. Hook System Removal and installation See diagram 9 Tools: 3/8" drive ratchet, 8 and 10 mm sockets, 8 and 10 mm ring- or open end spanners. General: Note length of bolts and positioning of washers for all assembly positions.
Page 82 Maintenance Manual LS10-s, -st Caution: The following items result in improper hook function: 1. Missing bushing >7< between drive levers below cable connector >1< 2. Cable below cross member of landing gear fork. 3. Wrong drive lever position at segment.
Page 83: Nose Hook System Removal And Installation
Maintenance Manual LS10-s, -st 4.6 Nose Hook System Removal and installation See diagram 9 Tools: 3/8" drive ratchet, 8 and 10 mm sockets, 3 and 4 mm hex head driver sockets, 10 mm ring spanner, 12 mm open end spanner.
Page 84 Maintenance Manual LS10-s, -st Disassembly and Assembly (continued) 4.4 Nose Hook System Assembly of nose hook is in reverse order, watch out especially for the following: (1) Insert spacer at position >6< inside hook body before assembly of lever extension.
Page 85: Removal And Installation Of The Flaperons
Maintenance Manual LS10-s, -st 4.7 Removal and installation of the flaperons 4.7.1 Removal of the flaperons 1. To remove the flaperons you have to remove the 18 m wingtips. 2. Carefully break away the fairings from the control surface horns at the flaperons.
Page 86 Maintenance Manual LS10-s, -st 9. 18 m wing tip: When removed from the inboard wing the flaperon is held in place by the internal sealing only. So to remove the flaperon you have to remove only the internal sealings, see section 4.8.3. Shift the flaperon inboards for removal.
Page 87: Control Surface Seals And Turbulators
4.8 Control surface seals and turbulators 4.8.1 Wings The LS10-s, -st are equipped with internal sealings on upper and lower surface. As an option Mylar strips may be installed to upper and lower wing surface to close the gaps. Note: To minimise the friction of the Mylar strips, the trailing edge of the strips should be chamfered.
Page 88 3 mm behind hinge cut-out. Be careful not to cut into the gel coat. (11) Proceed similary to item 2 up to 10 with the flaperon at the 18 m wing tip. Caution: Operating the LS10-s, -st without at least one (upper or lower side) internal sealing is prohibited.
Page 89 Maintenance Manual LS10-s, -st Material (see also parts list section 8): Denomination Required Teflon-Glass tape 0.1*50mm <0.004*1.97 in> 33 m <108 ft> Bonding film Tesafix 4965 translucent 9 mm <0.35 in> 33 m <108 ft> Contact glue (Pattex) Bonding film Tesafix 4965 translucent 9 mm <0.35 in>...
Page 90 Maintenance Manual LS10-s, -st 4.8.2 Horizontal tailplane sealing (1) Apply layer of Tesa film 4104 to elevator leading edge. (2) Bond plastic sealing tape after removing masking tape to elevator upper side. Protect leading edge of sealing tape with Tesa film 4104 against warping.
Page 91 Maintenance Manual LS10-s, -st 4.8.3 Rudder sealing Material (see parts list section 9): No. Denomination Required Scarfed convex Mylar tape, 30 mm <1.18 in> wide 2.3 m Tesafilm 4104 white 19 mm <0.75 in> 2.3 m Bonding film Tesafix 4965 translucent 9 mm <0.35 in>...
Page 92: Determination Of The Moments Of The Flaperons
Maintenance Manual LS10-s, -st 4.9 Determination of the moments of the flaperons Due to the flexibility of the flaperons and the large number of hinges it is very difficult to determine correct values for the moments. For the measurement you need a long flat working bench or a similar device.
Page 93 Maintenance Manual LS10-s, -st Start measurement at a 5 degree down position and lift the flaperon slowly to a 5° up position. Read spring balance. Lower the flaperon slowly to the 5° down position. Read spring balance. The load will be lower. Use the average of both values for the flaperon moment.
Page 94: Permanent Installation Of Fixed Ballast At Rear Fuselage
Maintenance Manual LS10-s, -st 4.10 Permanent Installation of fixed Ballast at rear Fuselage In special cases empty weight C.G. position may be shifted rearward to allow heavy pilots to fly with rearward in-flight C.G. positions. Therefore it is possible to install the following ballast at the tail:...
Page 95: Installation Of The Ballast Holder In The Fin
Maintenance Manual LS10-s, -st 4.11 Installation of the ballast holder in the fin 1. Remove the rudder according to section 1.3. 2. Disassemble the 4 lock-nuts M6 DIN985 St zn which fix the mounting brackets 4R3-40 for the elevator bellcrank to the fin shear web (see diagram 1).
Page 96: Working Instructions For Heat-Shrink Tubing
Maintenance Manual LS10-s, -st 4.13 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 97: Removal And Installation Of The Powerplant
Maintenance Manual LS10-s, -st 4.15 Removal and installation of the powerplant Tools: Ratchet, 8, 10, 17, 19 mm inserts, 12 mm hex head key, 19mm ring spanner Easiest removal and installation of engine is with wings derigged (see also diagrams 14 – 23). Disassembly of propeller not required.
Page 98 Maintenance Manual LS10-s, -st (13) Loosen M6 bolt between tower and gas strut. Push tower forward to take bolt out. Hold tower at crankshaft housing and lay down in engine bay. (14) Remove engine mount axle (bolt M12x200 DIN912-8.8 zn ), remove counter nut first.
Page 99 Maintenance Manual LS10-s, -st 4.15.2 Installation of the powerplant (1) Switch master “OFF”. Remove engine bay door tapes and open engine bay. (2) Undo fixing of retaining cable and of all electrical cables, Bowden cable and fuel lines. (3) Screw out engine mount axle.
Page 100 Maintenance Manual LS10-s, -st (15) Position clamp with gas strut for propeller stopper, switch rod and limit switches on lift cylinder marking and check or adjust for the following conditions: a) Firstly position clamp vertically on lift cylinder and check propeller stopper function according to section 1.15.6.
Page 101 Maintenance Manual LS10-s, -st (20) Functional check of sensors and limit switches: a) Extend engine completely using ignition switch, check proximity switch function (propeller position indicated on DEI-NT display). b) Turn propeller away from vertical and retract engine by ignition switch.
Page 102: Removal And Installation Of The Main Tank
Maintenance Manual LS10-s, -st 4.16 Removal and installation of the main tank Main tank removal and installation are only possible with wings derigged. 4.16.1 Disassembly of main tank (1) Drain main and feeder tanks completely via the drain valve (mounted behind LG box).
Page 103: Cleaning Of Decompression Valves
Maintenance Manual LS10-s, -st 4.17 Cleaning of Decompression Valves See diagram 17 Cleaning of both decompression valves at least every 5 years during the special engine inspection. Front deco-valve Deco-Bridge Deco-operation cable Deco-operation roller Thermag nut Engine mount Deco valves not air tight results in hissing noise during turning propeller by hand.
Page 104 Maintenance Manual LS10-s, -st (4) Decarbonize valves using petrol and fine steel wire brush. Rod must move freely, if needed disassemble valve after removal of retaining ring. (5) For re-installation use new sealing washer and torque 20 Nm (20 Nm;...
Page 105: Engine Ground Test Run
Maintenance Manual LS10-s, -st 4.18 Engine ground test run Starting engine on ground is possible only with suitable external starter motor. For this purpose the central propeller bolt has a hexagon head for connecting the external starter motor. Warning: This starting procedure is explicitly not recommended, because the procedure requires a lot of care and wariness to exclude danger.
Page 106: Heavy Fuel Odour In Fuselage
Maintenance Manual LS10-s, -st 4.19 Heavy Fuel Odour in Fuselage 1. Check all fuel line connections and fuel system part components for fuel- tightness; check especially connection between both tanks. 2. Check below tanks and fuel pumps for fuel discharge (The two stroke mix oil is visible for a long time).
Page 107: Replacement Of The Engine Retaining Cable
Maintenance Manual LS10-s, -st 4.20 Replacement of the engine retaining cable Please refer to diagram 20 1. Extend the powerplant. 2. Remove the engine retaining cable from the engine rear. 3. Support rear fuselage and remove tailwheel. 4. If not already installed cut an access hole into the tailwheel box dia. 32 mm <1.26 in.>...
Page 108 Maintenance Manual LS10-s, -st 10. Attach the new cable to the thin cable and pull it into the fuselage until the stopping sleeve is visible in the engine bay. 11. Disconnect the cable and push it through the lead-through part 4M01- 022.
Page 109: Removal And Installation Of The Engine Doors
Maintenance Manual LS10-s, -st 4.21 Removal and installation of the engine doors See diagram 21 Removal: 1. Extend the powerplant halfway via the manual switch. 2. Remove the engine door yoke 4GR-313. To accomplish this remove locknuts M4-DIN985 St zn (7 mm spanner) and bolts M4x50 DIN912-8.8 3.
Page 110: Dei-Nt Settings
Maintenance Manual LS10-s, -st 4.22 DEI-NT settings You will find a detailed description of the DEI-NT in flight manual section 7.4. In the SETUP-Menu different values can be entered. By persistently pressing the selector switch (for about 1 second, acknowledged by double audible signal), the display changes over from the flight screen to the SETUP screen.
Page 111 Maintenance Manual LS10-s, -st RES(ET). MAINT(ENANCE) TIMER: This mode is used to reset the remaining hours until next engine maintenance is due. Press selector switch, N (=No) appears, turning selector switch produces Y (=Yes). Short press on the switch results in command performed, i.e. with Y chosen, maintenance timer counter is reset to 25 hours of service interval time.
Page 112: Weight And Balance
Maintenance Manual LS10-s, -st 5 Weight and balance 1. Assemble the glider completely with gear down. Execute the weighing with all tanks empty, all removable ballast removed. Remove battery 3BR-199 out of the fin battery box. Only the safety bow (part 10L35) should remain in the battery box.
Page 113 Maintenance Manual LS10-s, -st The flight mass includes empty weight items plus pilot, parachute, trim ballast and all items needed in flight (barograph, camera, cushions, etc.). In addition, the rudder pedals and seating position should be adjusted as in flight.
Page 114: Instrumentation And Accessories List
Maintenance Manual LS10-s, -st 6 Instrumentation and accessories list Air speed indicator (0 - 300 km/h, 165 kts) LS10-s Manufacturer Type Certification No. Winter 6 FMS 4(diam. 80mm) TS 10.210/15 0-300 km/h Ident.No. LS-10-2 0-160 kts Ident.No. LS-10K-2 Winter 7 FMS 4(diam. 58mm) TS 10.210/19...
Page 115 Maintenance Manual LS10-s, -st Compass Type Manufacturer Certification No. B - 13 FD 19/77 Ludolph FK 16 10.410/3 Airpath C 2300 Airpath C 2400 P Hamilton H I 400 TSO C 7c Type1 Bohli 46 MFK 1 (only as additional equipment.)
Page 116 Maintenance Manual LS10-s, -st Turn and bank indicator Type Manufacturer Certification No. Apparatebau Gauting WZ-402/31 12 V 10.241/8 Outside air temperature gauge LS10-s: Störck TF-00-59K Installation of the sensor in the nose hook compartment. LS10-st: incorporated in the DEI-NT see below...
Page 117 Maintenance Manual LS10-s, -st Other instruments and equipment (eg. variometers, gliding computers or flight data recorders): Instruments and other equipment may be installed if they do not in themselves, or by their effect upon the sailplane, constitute a hazard to safe operation.
Page 118: List Of Special Tools
Maintenance Manual LS10-s, -st 7 List of special tools a) Special Equipment Tool Drawing Function Ratchet key 4F02-15 for assembly / disassembly of elevator and wing tips Filling funnel and tube Z201 for filling of water ballast system with wire meshing and...
Page 119: Partlist
Maintenance Manual LS10-s, -st 8 Partlist Please find the part no's of the control-system parts and of the metal fittings of the powerplant in the following diagrams. 8.1 Parts for the powerplant (only LS10-st) a) necessary for the 25 hours inspection 40050360 Spark plug S36 (Bosch W5AC Electrode gap 0,5 mm <0,02...
Page 120: Parts For The Electrical System
Maintenance Manual LS10-s, -st 8.2 Parts for the electrical system 45002070 Battery for power supply 12V/min.7Ah (2 installed) 60510478 master switch 60510385 circuit breaker ETA 2A (automatic cut out) 60510386 circuit breaker ETA 3A (automatic cut out) 60510387 circuit breaker ETA 4A (automatic cut out)
Page 121: Control Surface Sealings And Turbulators
Maintenance Manual LS10-s, -st 8.3 Control surface sealings and turbulators 1. Wings Wings and flaperons upper surface 70000253 bonding film Tesafix No. 4965, 9 mm <0.35 in>wide, 50 m <164◦ft> roll 30003143 Teflon glass tape 0,1 x 50 mm, 50 m <164◦ft> roll Wings and flaperons lower surface 30003143 Teflon glass tape 0,1 x 50 mm, 50 m <164◦ft>...
Page 122: Enclosures
Maintenance Manual LS10-s, -st 9 Enclosures 9.1 Equipment list 1 kg = 2.2046 lbs 25.4 mm = 1 in. Subject type mass arms date of date of installation removal Airspeed indicator Altimeter Variometer el. Variometer Compass Radio Transponder C. G. hook...
Page 123: Checklist For Checks And Maintenance Work (Only Ls10-St)
Maintenance Manual LS10-s, -st 9.2 Checklist for checks and maintenance work (only LS10-st) 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 124: Annual Inspection Checklist
Maintenance Manual LS10-s, -st 9.3 Annual Inspection Checklist Annual Inspection Checklist 1/4 Serial No.: Reg. Signs: Year of Manuf.: Wings 15m/18m tips Fuselage continued Part No. :______ Part No. :______ Control connectors Shell: finish, dents, cracks Shell: finish, dents, cracks...
Page 125 Maintenance Manual LS10-s, -st Annual Inspection Checklist 2/4 Serial No.: Reg. Signs: Year of Manuf.: Canopy Equipment Adjustments Part No. :______ Minimum instrumentation Wings and horizontal tail Locking mechanism Additional Instrumentation Tangential play Emergency release funct. Operating range marks Zero position of controls...
Page 126 Maintenance Manual LS10-s, -st Annual Inspection Checklist 3/4 Serial No.: Reg. Signs: Year of Manuf.: Check wing air brake levers for corrosion at lower end. Pull with about 25 kg <55 lbs> force at upper end of each lever in flight direction, simultaneously...
Page 127 Maintenance Manual LS10-s, -st Annual Inspection Checklist 4/4 only LS10-st Serial No.: Reg. Signs: Year of Manuf.: Engine (continued) Propeller Technoflug KS-1-G-079-L-050-W Every 25h or 12 Months (whichever occurs S/N. _________ first): Surface white Fuel filter in pump - clean...
Page 128: Checklist Engine Removal And Installation
Maintenance Manual LS10-s, -st 9.4 Checklist engine removal and installation Powerplant see MM section 4.15.1 Removal item description Install. Empty main and feeder tanks via drainer Extend engine completely, thereafter retract for about 5 degrees and switch master “OFF” Disassemble FRP-yoke for engine bay doors, mark fitting position and remove from bay.
Page 140 Pitot-/Static pressure system diagram 12 1 Multi Probe : Pitot-/Static-/TE pressure port 2 Pitot pressure port at fuselage nose. 3 Static pressure port for airspeed indicator and altimeter – forward fuselage sides. 4 Vacuum Bottles. E Capacity bottles for variometers Altimeter G Variometer switch (Option): Variometer...
Page 141: September
Fin RH side Fin LH side RH / LH side maintank 5 units depending on instrumentation Fire proof placard on main bulkhead on RH side on top of fin Above tailwheel LG door Part No.’s on all parts 31 31 33 optional on LH side LS10-st...
Page 142 Triebwerk Diagramm 14 Powerplant diagram 14 Ausgabe: September 2009 Issued: September 2009...
Page 143 Propellernabe Zusammenbau Diagramm 15 Propeller flange assembly diagram 15 Ausgabe: September 2009 Issued: September 2009...
Page 144 Propellerstopper Diagramm 16 Propeller stopper diagram 16 Ausgabe: September 2009 Issued: September 2009...
Page 145 Dekompressionsventile Diagramm 17 Decompression system diagram 17 Ausgabe: September 2009 Issued: September 2009...
Page 146 Ein-Ausfahrmechanismus Diagramm 18 Extension-Retraction mechanismus diagram 18 Ausgabe: September 2009 Issued: September 2009...
Page 147 Ausfahrendschalter Diagramm 19 Extension limit switch unit diagram 19 Ausgabe: September 2009 Issued: September 2009...
Page 149 Motorklappen Diagramm 21 Engine bay doors diagram 21 Ausgabe: September 2009 Issued: September 2009...

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