DG Flugzeugbau LS4 Manual de usuario

Maintenance Manual LS4

Issued: May 2011

Manual valid with the up-to-date cover page only

0-1

Recommendations to order spare parts

Please try to determine the exact designations of the spare parts for your order

using the maintenance manual. This is to guarantee a fast and correct delivery of

the parts.

The designations are to find in the sections system description, instructions for

assembly and servicing work and especially in the diagrams of the maintenance

manual.

Yours sincerely

DG FLUGZEUGBAU GMBH

Dipl.- Ing. W. Dirks

Maintenance Manual LS4

Issued: February 2019 TN4049

Manual valid with the up-to-date cover page only

0-2

0General

0.1 Manual amendments

No.

Page

Description

Date

0.1

all

Combination of the initial

Maintenance Manuals of

the Variants LS4, LS4-a

and

LS4-b, new standardized

format

May 2011

0.2

0-11, 1-1 ÷ 1-7, 1-10 ÷ 1-15,

2-1 ÷ 2-6, 2-15, 2-17, 2-20,

2-21, 2-23, 3-1 ÷ 3-4, 3-6, 3-

7, 4-1, 4-5 ÷ 4-7, 4-9, 4-16,

4-18 ÷ 4-20, 5-1 ÷ 5-3, 6-1,

7-6, 8-1, 9--1 ÷ 9-4,

10-1 ÷ 10-3, 11-1 ÷ 11-10

12-1, 12-2, 13-1,

14-3 ÷ 14-7

Miscellaneous changes to

the contents of the latest

amendments of the initial

maintenance manuals

May 2011

0-2, 0-4 - 0-6, 1-1, 2-2, 2-3,

2-5, 2-17, 4-6, 7-3, 7-5

neo-Winglets TN4049

February

2019

Maintenance Manual LS4

Issued: May 2011

Manual valid with the up-to-date cover page only

0-3

Page intentionally left blank

Maintenance Manual LS4

Issued: February 2019 TN4049

Manual valid with the up-to-date cover page only

0-4

0.2 List of effective pages

Section

page

issued

replaced

0-0

May 2011

0-1

See list of amendments

0-2

0-3

0-4

0-5

0-6

May 2011

0-7

0-8

0-9

0-10

0-11

1-1

May 2011

Febr. 2019

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-15

2-1

May 2011

2-2

“

Febr. 2019

2-3

“

Febr. 2019

2-4

“

2-5

“

Febr. 2019

2-6

“

2-7

“

2-8

“

2-9

“

2-10

“

2-11

2-12

Maintenance Manual LS4

Issued: February 2019 TN4049

Manual valid with the up-to-date cover page only

0-5

0.2 List of effective pages (continued)

Section

page

issued

replaced

2 cont.

2-13

May 2011

2-14

“

2-15

“

2-16

“

2-17

“

Febr. 2019

2-18

“

2-19

“

2-20

“

2-21

“

2-22

2-23

2-24

3-1

May 2011

3-2

3-3

3-4

3-5

3-6

3-7

4-1

May 2011

4-2

4-3

4-4

4-5

4-6

Febr. 2019

4-7

4-8

4-9

4-10

4-11

4-12

4-13

4-14

4-15

4-16

4-17

4-18

4-19

4-20

5-1

May 2011

5-2

5-3

5-4

Maintenance Manual LS4

Issued: February 2019 TN4049

Manual valid with the up-to-date cover page only

0-6

0.2 List of effective pages (continued)

Section

page

issued

replaced

5 cont.

5-5

May 2011

5-6

“

6-1

May 2011

7-1

May 2011

7-2

“

7-3

“

Febr. 2019

7-4

“

7-5

“

Febr. 2019

7-6

“

8-1

May 2011

8-2

8-3

9-1

May 2011

9-2

9-3

9-4

10-1

May 2011

10-2

10-3

11-1

May 2011

11-2

11-3

11-4

11-5

11-6

11-7

11-8

11-9

11-10

12-1

May 2011

12-2

13-1

May 2011

14-1

May 2011

14-2

14-3

14-4

14-5

14-6

14-7

Maintenance Manual LS4

Issued: May 2011

Manual valid with the up-to-date cover page only

0-7

0.3 Table of Contents

Section Content……………………………………………………………..page

0General.....................................................................................................0-2

0.1 Manual amendments................................................................................0-2

0.2 List of effective pages..............................................................................0-4

0.3 Table of Contents.....................................................................................0-7

0.4 Airworthiness Limitations .....................................................................0-11

0.4.1 Repairs..............................................................................................0-11

0.4.2 Life time of the airframe...................................................................0-11

0.4.3 Life time of equipment and components..........................................0-11

0.4.4 Service time, maintenance documents of equipment and components

..........................................................................................................0-11

1Description of systems.............................................................................1-1

1.1 Wings.......................................................................................................1-1

1.2 Aileron control.........................................................................................1-2

1.2.1 Aileron control LS4 and LS4-a ..........................................................1-2

1.2.2 Aileron control LS4-b.........................................................................1-2

1.3 Elevator Controls and Trim-System:.......................................................1-3

1.3.1 Elevator Controls................................................................................1-3

1.3.2 Trim Controls......................................................................................1-3

1.4 Rudder control system .............................................................................1-4

1.5 Wheel brake .............................................................................................1-4

1.6 Air brake controls ....................................................................................1-5

1.6.1 Air brake controls LS4 and LS4-a......................................................1-5

1.6.2 Air brake controls LS4-b....................................................................1-5

1.7 Water ballast system and sketches for wing control systems..................1-6

1.7.1 Water Ballast System LS4 and LS4-a................................................1-6

1.7.2 Water Ballast System LS4-b ..............................................................1-7

1.7.3 Wing control systems LS4 and LS4-a................................................1-8

1.7.4 Wing control systems LS4-b ..............................................................1-8

1.8 Cockpit.....................................................................................................1-9

1.8.1 Cockpit LS4 and LS4-a ......................................................................1-9

1.8.2 Cockpit LS4-b.....................................................................................1-9

1.9 Canopy.....................................................................................................1-9

1.9.1 Canopy LS4 and LS4-a.......................................................................1-9

1.9.2 Canopy LS4-b.....................................................................................1-9

1.9.3 Canopy LS4-b standard, LS4 and LS4-a with TN4032 executed....1-10

1.10 Instrument panel.....................................................................................1-10

1.10.1 LS4 and LS4-a instrument panel......................................................1-10

1.10.2 LS4-b instrument panel ....................................................................1-10

1.11 Baggage compartment ...........................................................................1-10

Maintenance Manual LS4

Issued: May 2011

Manual valid with the up-to-date cover page only

0-8

Section Content……………………………………………………………..page

1.12 Oxygen system.......................................................................................1-10

1.12.1 LS4 and LS4-a Oxygen system........................................................1-10

1.12.2 LS4-b Oxygen system ......................................................................1-10

1.13 Landing gear ..........................................................................................1-11

1.14 Wheel Brake...........................................................................................1-12

1.15 Hint for working at the control systems ................................................1-13

1.16 Pressure ports.........................................................................................1-14

1.16.1 Pressure ports LS4, LS4-a:...............................................................1-14

1.16.2 Pressure ports LS4-b:........................................................................1-14

1.17 Drain orifices .........................................................................................1-15

1.18 Colour coding of instrument lines .........................................................1-15

2Mass and balance.....................................................................................2-1

2.1 Weighing procedure.................................................................................2-1

2.2 Calculation of loading limits, example....................................................2-3

2.2.1 Calculation of loading limits ..............................................................2-3

2.2.2 Examples for calculation of loading limits.........................................2-5

2.3 Empty mass C.G. range ...........................................................................2-6

2.4 Max. mass of non-lifting parts...............................................................2-17

2.4.1 Calculation of max. mass of non-lifting parts (standard water bags) .....

...................................................................................................... 2-17

2.4.2 Calculation of max. mass of non-lifting parts according to TN 4046

with water bags V112 according to TN 4047...................................2-21

3Inspections ...............................................................................................3-1

3.1 Regular inspections..................................................................................3-1

3.1.1 Daily Inspections................................................................................3-1

3.1.2 Annual Inspections .............................................................................3-1

3.2 Extraordinary inspections after heavy landings.......................................3-5

3.3 Inspection procedure for increase of service time...................................3-6

3.4 Lubrication schedule................................................................................3-7

4Working instructions................................................................................4-1

4.1 Removal and installation of control surfaces...........................................4-1

4.1.1 Ailerons...............................................................................................4-1

4.1.2 Elevator...............................................................................................4-3

4.1.3 Rudder.................................................................................................4-4

4.2 Installation of control surface gap sealings and turbulators ....................4-5

4.2.1 Installation of internal seals................................................................4-5

4.2.2 Gap seals aileron.................................................................................4-6

4.2.3 Gap sealings elevator..........................................................................4-7

4.2.4 Gap seals rudder .................................................................................4-7

4.2.5 Turbulator on lower wing surface ......................................................4-8

Maintenance Manual LS4

Issued: May 2011

Manual valid with the up-to-date cover page only

0-9

Section Content……………………………………………………………..page

4.3 Removal and installation of seat shell .....................................................4-9

4.3.1 Removal and installation of seat shell LS4 and LS4-a.......................4-9

4.3.2 Removal and installation of seat shell LS4-b.....................................4-9

4.4 Adjustment of water ballast valves........................................................4-11

4.5 Removal and installation of the wing water ballast bags:.....................4-12

4.5.1 Removal of the wing water ballast bags...........................................4-12

4.5.2 Assembly of the wing water ballast bags.........................................4-13

4.5.3 Installation of the wing water ballast bags.......................................4-14

4.6 Removal and installation of the tail fin water ballast tank (Option) .....4-15

4.6.1 Tail fin water ballast tank removal...................................................4-15

4.6.2 Tail fin water ballast tank installation:.............................................4-15

4.7 Removal and installation of the C.G. Hook...........................................4-16

4.7.1 Removal of the C.G. Hook...............................................................4-16

4.7.2 Installation of the C.G. hook ............................................................4-16

4.8 Removal and installation of the nose hook (Option).............................4-18

4.8.1 Removal of the nose hook................................................................4-18

4.8.2 Installation of nose hook...................................................................4-18

4.9 Canopy emergency release ....................................................................4-19

5Control surfaces .......................................................................................5-1

5.1 Control surface deflection limits..............................................................5-1

5.2 Control surface weight and mass balance................................................5-2

5.3 Control surfaces free play........................................................................5-3

5.4 Control surfaces friction ..........................................................................5-3

5.5 Limit values for control surface deflections in mm/in. ,only LS4-b.......5-4

6Special tools:............................................................................................6-1

7Placards and markings .............................................................................7-1

7.1 Placards and markings LS4......................................................................7-1

7.2 Placards and markings LS4-a .................................................................7-3

7.3 Placards and markings LS4-b.................................................................7-5

8Permanent installation of fixed ballast and equipment............................8-1

8.1 Fixed ballast under instrument panel.......................................................8-1

8.2 Fixed Ballast at rear fuselage end............................................................8-2

8.3 Permanent installation of equipment in baggage compartment...............8-3

Maintenance Manual LS4

Issued: May 2011

Manual valid with the up-to-date cover page only

0-10

Section Content……………………………………………………………..page

9Instruments- and Equipment List (Master Equipment List)....................9-1

9.1 Airspeed Indicator....................................................................................9-1

9.2 Altimeter ..................................................................................................9-2

9.3 Seat Belt Harness (with multiple point buckles) .....................................9-2

9.4 Compass...................................................................................................9-2

9.5 UHF –Transmitter and Receiver.............................................................9-3

9.6 Variometer ...............................................................................................9-3

9.7 Turn and Bank Indicator..........................................................................9-3

9.8 Thermometer............................................................................................9-4

9.9 Electrical Supply......................................................................................9-4

9.10 Equipment, not being part of minimum equipment:................................9-4

10 Materials for repair ................................................................................10-1

11 Repairs ...................................................................................................11-1

11.1 Preface....................................................................................................11-1

11.2 Repairs of composite structures, General..............................................11-2

11.3 Tools and facilities required ..................................................................11-3

11.4 Instructions for FRP repairs...................................................................11-4

11.4.1 General..............................................................................................11-4

11.4.2 Repairs of a FRP shell......................................................................11-4

11.4.3 Repairing the outer skin of a foam sandwich panel ........................11-4

11.4.4 Repair of outer and inner skin of a sandwich panel.........................11-5

11.4.5 Repairing small dents in a sandwich panel skin (no cracks in the

gelcoat) .............................................................................................11-5

11.4.6 Outer skin finish ...............................................................................11-6

11.4.7 Repairing control surfaces................................................................11-6

11.5 Types of materials and overlap dimensions...........................................11-7

11.6 Control cables and connections .............................................................11-9

11.7 Longitudinal motion pushrod bearings................................................11-10

12 Recommendations for maintenance and care of gelcoat surfaces.........12-1

12.1 General...................................................................................................12-1

12.2 "Schwabbel" procedure:.........................................................................12-2

13 Transport of sailplane ............................................................................13-1

13.1 Support areas for road-transport............................................................13-1

13.2 Support areas when lifting the entire plane ...........................................13-1

13.3 Ground Towing......................................................................................13-1

14 Appendix................................................................................................14-1

14.1 Annual inspection checklist...................................................................14-1

14.2 Instruction for maintenance of L’Hotellier ball and swivel joints ........14-4

Este manual sirve para los siguientes modelos

Tabla de contenidos

Manuales populares de Cepilladora de otras marcas

Felisatti

Felisatti PF180/1500 Manual de usuario

DeWalt

DeWalt DW 1150 Guía

Triton

Triton TRP UL Guía rápida

Melbourne

Melbourne MTC-49407 Manual de usuario

VARO

VARO POWERplus POW1520 Manual de usuario

Powermatic

Powermatic 209 Manual de servicio

Skil

Skil 1565 Manual de usuario

Makita

Makita 1051D Manual de usuario

Scheppach

Scheppach Plana 3.0 Instrucciones de montaje

Grizzly

Grizzly G1033X Manual de usuario

Stanley

Stanley STPP7502 Manual de usuario

Palmgren

Palmgren 84115 Manual de usuario

Draper

Draper PT610V Manual de usuario

Makita

Makita PC5000C Manual de usuario

Berner

Berner BP 40-82 C Manual de usuario

Grizzly

Grizzly G0603X Manual de usuario

King Industrial

King Industrial CT-381FX Manual de usuario

FXA

FXA FXAJD8220 Manual de usuario