SAIB CE-02-07

SPECIAL

AIRWORTHINESS

INFORMATION

BULLETIN Aircraft Certification Service Washington, DC U.S. Department of Transportation Federal Aviation Administration No. CE-02-07 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 Model DG-500 series sailplane owners on the following:

• Aircraft Lubrication

• Proper securing of the head rest in the rear cockpit

• Flight and Maintenance Manual Revision Pages Safety Issue DG Flugzeugbau has developed Technical Note 348/15 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. The FAA highly recommends that you comply with the intent of the Technical Note.

Recommendation We highly recommend that you, an owner or operator of Flugzeugbau Models DG-500 series sailplanes, comply with the intent of Technical Note 348/15.

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.

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. 348/15 Subject : Greasing schedule / manual revision Effectivity : DG-500 all modeis, all serial no.'s Accomplishment : 31.03.2001 Reason : I. 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.

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

4. 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 348/15.

Model Flight manual Maintenance manual DG-500 Trainer 0.1, 0.3, 0.4, 4.5, 7.7, 8.2 1, 2,24 DG-500 Orion 0.1, 0.3, 0.4, 4.7, 7.6, 8.2 1, 2,25 DG-500/20 0.1, 0.3, 0.4, 4.7, 7.7, 8.2 1, 2, 9, 17, 26 DG-500/22 0.1, 0.3, 0.4, 4.7, 7.7, 8.2 1, 2,9,26 Material : Multi-purpose greases for rolling element bearings Nylon or Perlon 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 IN has been approved by Dipl. Ing. Wilhelm Dirks the LBA under the date of Feb.7.Zaand is signed by MA Slume W.O. Mr. Fendt The translation into English has been done by best knowledge and judgement.

Type certification inspector:

Dipl. Ing. Swen Lehner Scen Felin 2

Flight manual DG-500 ELAN TRAINER

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 0.3,2.8, TN 348/1T Mar. 92 31.03.92

2.9,4.8 2 0.4,7.2 IN 348/3T Oct. 92 08.12.92

0.3,1.2, IN 348/4T oct. 94 26.10.94

4.14

0.3,0.4, IN 348/9 Oct. 97 26.11.97

1.3,4.1,

4.2,4.3,

5.2,5.5,

5.6,6.2,

6.4,6.7,

7.1,7.9,

7.10 5 0.3, 0. 4, TN 348/15 Jan. 01 07.02.01

4.5, 7.7,

8.2 Issued: see last item 0.1 3

Flight manual DG-500 ELAN TRAINER

0.2 List of effective pages Section page issued replaced replaced

0.0 мау 90

0.1

0.2

0.3 May 90 Oct. 94 Oct. 97 Jan. 01

0.4 Oct. 92 Oct. 97 Jan. 01

0.5

1.1

1.2 Dec. 90

1.3 May 90 Oct. 97

1.4

1.5 2 2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8 2.9 March 92

3.1

3.2

3.3

4.1 Oct. 97

4.2 Oct. 97

4.3 Oct. 97

4.4

4.5 Jan. 01

4. 6

4.7

4.8

4.9

4.10 App. 4.11 March 92

4.12

4.13

4.14 Oct. 94

4.15 May 90 Issued: January 2001 TN 348/15 0.3 4

Flight manual DG-500 ELAN TRAINER

0.2 List of effective pages (cont.)

Section page issued replaced replaced 5 5.1 May 90

5.2 Oct. 97

5.3 APP • 5.4

5.5 Oct. 97

5.6 Oct. 97

5.7

6.1

6.2 Oct. 97

6.3

6.4 Oct. 97

6.5

6.6

6.7 Oct. 97

7.1 oct. 91

7.2 Oct. 92

7.3

7.4

7.5

7.6

7.7 Jan. 01

7.8

7.9 Oct. 97

7.10 Oct. 97

8.1 8.2 May 90 Jan. 01

8.3

8.4

8.5

9.1 May 90 Issued: January 2001 IN 348/15 0.4 5

Flight manual DG500 ELAN TRAINER B Inspection after rigging Walk around the aircraft

1. All parts of the airframe

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

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

2. Cockpit area

a) check the canopy locking mechanism 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 ₫) 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 radio and other electrical equipment for function. If there is no electric power it must be assumed, that the battery is not in-stalled in the fin. Flying is only allowed with the battery in the fin as otherwise the forward C.G. limit may be exceeded.

1) check the brake fluid level

3. C.G. Tow hook

a) c heck the ring muzzle of the C.G. hook for wear and function

b) check for cleanliness and corrosion

4. Main landing gear and nose wheel

a) check the struts, the gear box, the gear doors and the tyre for wear; dirt in the struts can hinder the landing gear from locking over center the next time!

Issued: January 2001 TN348/15 App. 4.5 6

Flight manual DG-500 ELAN TRAINER

b) Tailwheel: Tyre 200 × 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 nooks are operated by the same handle.

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.

Issued: January 2001 TN348/15 7.7 7

Flight manual DG-500 ELAN TRAINER

8.1 Introduction This section contains manufacturer's recommended procedures for proper ground handing 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-500 ELAN TRAINER 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).

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-500 ELAN TRAINER repair manual. No repairs should be carried out without referring to the manua.

Issued: January 2001 TN348/15 8.2 8

Maintenance manual DG-500 ELAN TRAINER Manual amendments Rev. Page Description Date Signature No 1 3, Diagr. 9 TN 348/1T March 92 2, 3, 7, 8, 14, 15, TN 348/3T Oct. 92 17,18,23,25,34 3, Diagr. 7 AM 500/7/93 June 93 4 2,3,17 TN 348/4T Oct. 94 Instruction for inspection, questionaire, working instructions No.1 and No.2 for TN 348/4 5 2,4,15,18,21, TN 348/9 Oct. 97 25 12, 24 TN 348/9 Jan. . 01 Issued: see last item 9

Instructions for continued airworthiness Maintenance manual DG-500 ELAN TRAINER LBA Content Page approved Airworthiness limitations Oct. 97 System description and issued adjustment data

1.1 Wing and tailgroup setting data 5

1.2 Elevator control and trim system 7 Oct: 92

1.3 Rudder control 8

1.4 Aileron control 9 10

1.5 Airbrake control and wheel brake 11

1.6 Undercarriage 12 13

1.7 Tow hooks 14 Oct. 92

1.8 Sectionnot effective

1.9 Massbalance and weights of controi surface 15 Oct. 97

1.10 Fore and aft play of the wings 16 July 90

2. Inspections

2.1 2.2 Daily inspection Regular inspections 17 17 oct. 94

2.3 Inspection after a heavy landing 18 Oct. 97 19 20

2.4 Inspection procedure for increase 21 Oct. 97 of service time 22 July 90

3. Maintenance

3.1 General maintenance 23 Oct. 92

3.2 Maintenance of the airframe 24 Jan. 01

3.3 Greasing programme 24

3.4 Damage of the airframe 25 Oct. 97

3.5 Hydraulic brake system 25 Oct. 97

4. Detailed instructions for assembly and servicing work

4.1 Section not effective

4.2 Replacement of control cables

4.3 Adjustment and servicing of the control circuit

4. 4 Removal and installation of the 28 undercarriage 29

4.5 Filling and bleeding the hydraulic 30 disc wheel brake

4.6 Removal and installation of the under- 31 Carriage (non retractable) Issued: January 2001 TN 348/15 10

Maintenance manual DG-500 ELAN TRAINER

3. Maintenance

3.2 Maintenance of the airframe The saiplane 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.

33).

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.

Once a year your DG-500 ELAN TRAINER 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.

- Remove 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, ailerons, airbrakes and elevator control.

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

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 SFW39 on 5St68/2 and airbrake control handle 5St69 on 5St68/.

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

Issued: January 2001 TN 348/15 24 11