SAIB CE-02-06

SPECIAL

AIRWORTHINESS

INFORMATION

BULLETIN Aircraft Certification Service Washington, DC U.S. Department of Transportation Federal Aviation Administration No. CE-02-06 November 9, 2001 We post SAIBs on the internet at "av-info.faa.gov" This is information only. Recommendations are not mandatory.

Introduction This Special Airworthiness Information Bulletin (SAIB) recommends safety information to DG Flugzeugbau Models DG-500M and DG-500MB sailplane owners on the following:

• Aircraft Lubrication

• Proper securing of the head rest in the rear cockpit

• Improved carburetor control lever (applicable to the DG-500MB)

• Flight and Maintenance Manual Revision Pages Safety Issue DG Flugzeugbau has developed Technical Note 834/16 that contains the detailed information for the airworthiness concerns listed above.

A copy of the DG Flugzeugbau Technical Note is included for your information with the respective Flight and Maintenance Manual pages.

Recommendation We highly recommend that you, an owner or operator of Flugzeugbau Models DG-500M and DG- 500MB sailplanes, comply with the intent of Technical Note 834/16.

For Technical Information Concerning These Safety Issues Contact DG Flugzeugbau GmbH, Im Schollengarten 20, D 76646 Bruchsal, Federal Republic of Germany;

telephone 49.7257.890; facsimile 49.7257.8922.

For Further Information Contact Oliver Dyer-Bennet, DG USA (United States Dealer), 5847 Sharp Road, Calistoga CA 94515;

telephone (707) 942-5727; facsimile (707) 942-0885.

Mike Kiesov, Aerospace Engineer/Pilot, FAA, Small Airplane Directorate, 901 Locust, Room 301, Kansas City, Missouri, 64106; telephone: (816) 329-4144; facsimile: (816) 329-4090; email:

mike.kiesov@faa.gov.

DG Flugzeugbau GmbH Technical Note page 1 from 1 76646 Bruchsal No. 843/16 Subject : Greasing schedule / manual revision Effectivity : DG-500M all serial no., DG-500MB all serial no.

Accomplishment : 31.03.2001 Reason : 1. The greasing schedule in the maintenance manual does not point out the bearings which are accessible via the access panels in both cockpits, so it must be assumed that on some gliders these bearings have never been serviced.

2. The time between lubrications can be increased to 1 year due to service experience.

3. The securing ropes of the head rest in the rear cockpit must prevent the head-rest from interfering with the rear control stick when the head rest is moved to its most forward position.

4. On the DG-500MB the carburettor control lever was replaced by an improved lever from ser. no. 5E213 and on. This new lever can also be installed on earlier ser.nos. as an option.

5. Some manual corrections.

Instructions : 1. Remove the access panels (2 in the front and 2 in the rear cockpit): You have to remove the height adjustable seat pan from the rear cockpit first. Clean and grease all accessible bearings (ball bearings and rod ends with universal bearings).

Reinstall access panels and seat pan.

2. Check the securing ropes of the head rest in the rear cockpit for wear and correct length. The securing ropes must prevent the head rest from interfering with the rear control stick when the head rest is moved to its most forward position.

3. Exchange the following manual pages against new pages issued January 2001 marked with TN 843/16:

Model Flight manual Maintenance manual DG-500 M 0.1, 0.3, 0.5, 4.8, 1, 2, 3, 11, 45, 63

7.14, 8.2 DG-500 MB 0.1, 0.3, 4.8 1, 2, 3, 4, 11, 19, 27, 45, 47,48, 49, 51, 54, 62, 71, 79, 91 wiring scheme 5E101 (issued

10.05.00), drawing W40 (issued 30.11.99) Material : Multi-purpose greases for rolling element bearings Nyion or Perion cord 3mm Manual pages see instruction 3 Weight and balance : / Remarks : All instructions may be executed by the owner. They have to be inspected and entered in the aircraft logs by a licensed inspector with the next annual inspection.

Bruchsal, date: LBA - approved:

January 26. 2001 Author: The German original of this TN has been approved by Dipl. Ing. Wilhelm Dirks the LBA under the date of Feb. 7. 2001 and is signed by Wilhelm O by best knowledge and judgement. Mr. Blume. The translation into English has been done Type certification inspector:

Dipl. Ing. Swen Lehner Swen Zelme 2

Flight manual DG-500M

0.1 Record of revisions Any revision of the present manual, except actual weighing data, must be recorded in the following table and in case of approved sections endorsed by the responsible airworthiness authority.

The new or amended text in the revised page will be indicated by a black vertical line in the right hand margin, and the Revision No. and the date will be shown on the bottom left hand of the page.

Rev. Affected Description Issue LBA Inserted No. Pages/ Date Approval Date section Date Signature 1 0.3-0.5, TN 843/2 Febr. 92 March 04, 92

2.6,4.10

4.15,4.17 2 0.1,0.3, TN 843/5 Sept. 92 Dec. 08, 92

0.4,0.5,

3.4,6.6,6.7,7.2,7.7,7.8,8.7 3 O.1,0.3, TN 843/7 Febr.96 April 08, 96

0.4,0.5,

2.6,2.8,2.10,

4.12,4.13,5.9,

6.5,6.9,7.17,7.18,8.2,8.6 4 0.1,0.3,2.6 TN 843/8 March 97 05.06.97 5 0.1, 0.5, 7.11 TN 843/11 Dec. 98 Dec. 17, 98

0.1, 0.3, 0.5, TN 843/16 Jan. 01 07.02.01

4.8, 7.14, 8.2 Issued: see last item 0.1 3

Flight manual DG-500M

0.2 List of effective pages Section page issued Replaced/ replaced/ replaced

0.0 April 89

0.1

0.2

0.3 see record of revisions

0.4

0.5

0.6 April 89

1.1 Febr. 91 April 89 Febr. 92/ Febr.96/ March 97 Febr.96 Febr. 96 Sept.92

4.4

4.5

4.6

4.7

4.8 Jan. 01

4.9

4.10 Febr.92 App. 4.11 April 89 Issued: January 2001 TN 843/16 0.3 4

Flight manual DG-500M

0.2 List of effective pages (cont.)

Section page issued replaced replaced 7 7.1 April 89

7.2 Sept. 92

7.3

7.4

7.5

7.6

7.7 Sept. 92

7.8 " 19

7.9

7.10

7.11 Aug. 90 Dec. 98

7.12

7.13

7.14 Jan. 01

7.15

7.16

7.17 Febr. 96

7.18 8 8.1

8.2 Febr. 96 Jan. 01

8.3

8.4

8.5

8.6 Febr. 96

8.7 Sept. 92 9 9.1 April 89 Issued: January 2001 TN 843/16 0.5 5

Flight manual DG500 M B Inspection after rigging Walk around the aircraft

(6) ®

1. All parts of the airframe

a) check for flaws such as bubbles, holes, bumps and cracks in the surface

b) check leading and trailingedges of the wings and control surfaces for cracks

2. Cockpit area

a) check the canopy locking mechanism

b) check the canopy emergency release see sect. 7.15 (not each day, but min. every 3 month)

c) check the main pin securing check the securing ropes of the headrest in the rear cockpit for wear and function

d) check all controls for wear and function, incl. positive control check

e) check the tow release system for wear and function incl. cable release check ‡) check for foreign objects

g) check the instrumentation and radio for wear and function

h) check the brake fluid level

1) check the fuel filter for dirt and sludge

j) check the engine controls

k) check all fuses including the battery fuse check the extension-retraction mechanism by operating it in both directions. The extension time should not exceed 13 seconds!

Note: If the mechanism can't be operated with the ignition switch or with the manual switch, check the circuit breaker.

m) extend the engine with the manual switch Issued: January 2001 TN843/16 App. 4.8 6

Flight manual DG-500M

b) Tailwheel: Tyre 200 x 50 2 PR Diameter 200 mm (7.87 in) Tyre pressure 4 bar (58 psi)

c) Nosewheel: Tyre 260 × 85 Diameter 260 mm (10.2 in.)

Tyre pressure 2.5 bar (36 psi) Option: See diagram 10 M.M.

The nose wheel is connected to the rudder control with springs.

7.5 Tow hooks See diagram 5 M.M.

Safety release "Europa G 88" for winch launch installed near the C.G "nose release E 85" installed in the fuselage nose for aerotow.

Both hooks are operated by the same handle.

7.8 Seats and safety harness The front seat is constructed as an integral inner shell.

The rear seat is height adjustable. The adjustment is by means of a strap similar to the shoulder harness.

As safety harness only symmetric 4-point harnesses fixed at the given fixing points are allowed.

7.9 Baggage compartment Max. load 15 kg (33 Ibs.).

Heavy pieces of baggage must to be secured to the floor.

7.10 Waterballast system See diagram 6 M.M.

The wingtanks are constructed as double wall bags with a capacity of 50 1

(13.2 U.S.gal) per wing. The dump valves are mounted in the wings and the control is hooked up automatically when rigging the glider.

Issued: January 2001 TN843/16 7.14 7

Flight manual DG-500M

8.1 Introduction This section contains manufacturer's reconnended procedures for proper ground handling and servicing of the sailplane. It also identifies certain inspection and maintenance requirements which must be followed if the sailplane is to retain that new-plane performance and dependability. It is wise to follow a planned schedule of lubrication and preventive maintenance based on climatic and flying conditions encountered.

8.2 Inspection period, maintenance The 'Instructions for continued airworthiness (maintenance manual) for the DG-500M have to be followed.

A Before each rigging all the connecting pins and bushes should be cleaned and greased. This includes the control connectors.

B The contact surfaces of the canopies to the fuselage are to be rubbed with colourless floor-polish (canopy and fuselage side) to reduce grating noise in flight. Polish at the beginning of the flight season and then every month.

C Once a year all the bearings and hinges should be cleaned and greased. See the greasing programme of the maintenance manual.

Each year the control surface displacements, adjustments and general condition must be checked. (See the maintenance manual).

D Maintenance of the engine see maintenance manual sect. 3.

8.3 Alterations or repairs It is essential that the responsible airworthiness authority be contacted prior to any alterations on the airplane, to ensure that the airworthiness of the sailplane is not impaired. It is prohibited to execute the alteration without the approval of the airworthiness authority. The manufacturer will not be liable for the alteration or for damages resulting from changes in the characteristics of the aircraft due to alteration. So it is strongly recommended to execute no alternatives which are not approved by the aircraft manufacturer.

External loads such as external camera installations are to be regarded as alterations! Repair instructions can be found in the DG-500M repair manual. No repairs should be carried out without referring to the manual.

Issued: January 2001 TN843/16 8.2

Maintenance manual DG-500M Manual amendments No. Page Description Date Signature 3, 4, 49, 65, TN 843/2 Febr.92 67, 68, 88, 89, 91, 99 diagr. 11 1-4, 6, 9, TN 843/5 Sept.92 11, 17, 19, 37, 39, 40, 44, 46, 49-51, 66-69, 75, 81, 88, 91; 93 diagram 11, service-information 0-2/92 3 1-6, 24, 25, TN 843/7 Febr.96 26, 32, 37, 37a, 376, 37c, 37d, 40, 42, 49 , 50, 52, 59, 77, 85, 85a, 85b, 88, 89, 90, 92, diagram 6,8,13, drawing SEI 1, 3, 4, 47 TN 843/8 March 97 59, 92, diagr. 11 5 3,52 TN 843/9 Oct. 97 1, 2, 3, 11, 45 TN 843/16 Jan. 01 63 Issued: see last item

Maintenance manual DG-500M Instructions for continued airworthiness LBA Content Page approved Airworthiness limitations 5 Febr.96 6 I. System description and adjustment data issued

1.1 Wing and tailgroup setting data 7 July 90

1.2 Elevator control and trim system 8 9 Sept. 92

1.3 Rudder control 10 July 90

1.4 Aileron and wing flaps control 11 Jan. 01 12 July 90

• 13

1.5 Airbrake control and wheel brake ￾ 14 " :•

1.6 Undercarriage • 15

• 16

1.7 Tow hooks 17 Sept. 92

1.8 Waterballast 18 July 90

1.9 Massbalance of control surfaces 19 Sept. 92

1.10 Fore and aft play of the wings 20 July 90 Power plant 21 .. .

22 23

1.12 Retraction-extension mechanism 24 Febr.96

1.13 Fuel system 25 26 27 July 90 28 29

1.14 Electrical system 30 31 32 Febr.96

• 33 July 90 34 35 36

2. Inspections

2.1 Daily inspection 37 Sept.92

2.2 Regular inspections 37 Febr.96 Inspection program 37a Inspection after rigging 376 37c 37d 38

2.3 Inspection after a heavy landing 39 Sept. 92 40 Febr. 96 41 July 90 Issued: January 2001 TN 843/16 2 10

Maintenance manual DG-500M Instructions for continued airworthiness Content Page issued

2.4 Inspection procedure for increase of 42 Febr.96 service time 43 July 90

3. Maintenance

3.1 General maintenance 44 Sept. 92

3.2 3.3 Greasing programme Maintenance of the airframe 45 45 Jan. °1

3.4 Damage of the airframe 46 Sept. 92

3.5 Maintenance of the powerplant 47 March 97 48 • July 90 49 Febr. 96 50 51 Sept. 92 52 Febr. 96

4. Detailed instructions for assembly and servicing work

4.1 Replacement of the water ballast bags and servicing of the valves Keplacement of control cables 53 54 July 90 Adjustment and servicing of the control circuit 54

4.4 Removal and installation of the 55 undercarriage 56

4.5 Filling and bleeding the hydraulic 57 disc wheel brake 58

4.6 Working instructions for heat-shrink tubing 59 Febr. 96 +. / Securing with Loctite 72 b - 59 March 97

4.8 Instructions for securing the propeller bolts 60 July 90

4.9 Filling and bleeding the cooling system 61 62

4.10 Replacement of wing fuel tanks 63 Jan. 01

4.11 Inspection of rotary valve wear 64 July 90

4.12 Checking the ignition unit 65 Febr. 92 66 Sept. 92

4.13 Ignition unit-trouble shooting 69

4.14 Instructions for the removal and 70 July 90 refitting of magneto flywheel ass') 71 and exchange of starter gear 72

4.15 Mounting and tensioning of the 73 drive belt 74

4.16 keplacing the bearings of the 75 Sept. 92 ipper pulley SMIl 76 July 90

4.17 Replacement of the extension-retraction mechanism and the gas strut 77 Febr. 96 Issued: January 2001 IN 843/16 3 11

Maintenance manual DG-500M

1.4 Aileron and wing flap control

1.4.1 Control circuit (see diagrams 3 and 4) A spring at the mixer shaft 5St60 provides additional aileron return force at positive wing flap settings.

1.4.2 Deflections and tolerances 64 + 3 mm (2.52 + 0.12 in.)

down 10° + 1° 32 + 3 mm (1.26 + 0.12 in.)

measured at 182 mm (7.17 in.) from hinge axis (at the aileron root), wing flap setting 0°.

Wing flap deflections:

- 10° - 40 + 3 mm (1.57 + 0.12 1n.)

L = + 15° + 59 + 3 mm (2.32 + 0.12 in.)

measured at 228 mm (9.0 in.) from hinge axis against the fixed part at the wing root. At flap setting 0° the wingflaps have to be adjusted against the fixed part at the wing root with 0 + 1 mm (0 + 0.04 in.).

1.4.3 Stops The aileron stops are located at the rear control column and can be adjusted with two 10 min open-end wrenches.

The stop for positive wingflap setting is located under the removable lefthand side panel of the rear seat on the pushrod of the wingflap handle 5St73.

The sleeve which is riveted to the rod must stop at the main bulkhead in landing setting. Adjustment is by adjusting the rear pushrod 5St74 against 5St73.

The stop for negative setting (front) is located in the front cockpit on the inner guiding tube SST68/2 of the front wingflap handle SSt72.

Adjustment by placing shims with inside diameter 12 mm (0.47 in.)

between 5ST72 and the sleeve which is riveted to 5St68/2.

Issued: January 2001 TN843/16 11 12

Maintenance manual DG-500M

3. Maintenance

3.2 Maintenance of the airframe The sailplane is service free except for the care of the surfaces (see sect. 3.1) and greasing and oiling of the control system and all pins (see sect.

3.3).

After a landing in a soft field, the undercarriage box and tow hook should be thoroughly cleaned.

3.3 Greasing and oiling A The contact surfaces of the canopies to the fuselage are to be rubbed with colourless floor-polish (canopy and fuselage side) to reduce grating noise in flight. Polish at the beginning of the flight season and then every month.

B Once a year your DG-500M 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 connections at the inboard aileron.

- Airbrake drive connection - in airbrake box, also grease the brake paddle pivots.

- Remove the access panels on the left hand cockpit walls and grease all the pushrod guides, but not those with Teflon linings, note see below.

- Renove the baggage compartment floors and open the baggage compartment rear cover to grease all bearings.

- Open the access panels (2 in the front and 2 in the rear cockpit). In the rear cockpit you have to remove the height adjustable seat pan first. Grease all accessible bearings (ball bearings and rod ends with universal bearings)

- Remove the control column covers and grease all the bearings associated with the control columns.

- Grease the rudder pedal adjustment slide.

Oil all hinge points on the undercarriage in the undercarriage box.

Clean and grease all control surfaces hinges.

- Clean and grease the control hook ups for wing flaps, ailerons, airbrakes and elevator control.

- Clean and grease all pins and bushes of the wing and tailplane attachment.

- Grease the powerplant see sect. 3.5 Note: The greases we recommend are lithium based pressure-resistant anticorrosion greases or lithium-soap greases (multi-purpose greases for rolling element bearings).

Note: The sliding guides of the following parts are made from Teflon and should not be greased:

Landing gear controlhandle 5FW39 on 5St68/2, Airbrake control handle 5S169 on 5St68/1 and wingflaps handle 5St72 on 5 St68/2.

If these parts have been greased inadvertently you have to disassemble the parts and to clean them completely with Acetone.

Issued: January 2001 TN843/16 45 13

Maintenance manual DG-500M

4.10 Replacement of wing fuel tanks Uniroyal rubber fuelbags 4F28

a) Disconnect the plastic fuel line inside the wing at the quick connector attached to the wing root rib. Loosen the perlon cords marked red and black at their attachment at the root rib.

Attach an extension cord 3 mm (1/8 in.) diameter 5 m long to the red perlon cord. Remove the fuel tank by pulling on the black perlon cord and on the fuel line. Disconnect the wire for the electrostatic connection.

b) Replacement is done by reversing the above procedures.

Attach the wire for the electrostatic connection by use of a poprivet see sketch, if there is no plug installed.

eir e _ poprivet ø4

- Connector A4-1 DIN 46225 washers 4,3 DIN 9021 Issued: January 2001 TN843/16 63 14