chsal • Germany 

ail: dg@dg-flugzeugbau.de 

• lager@dg-flugzeugbau.de 

MANUAL 

E 

DER 

8C 

___________ 

___________ 

Maintenance Manual DG-808C 

Issued: April 2009 TN800/35 0.10 General 0.1 Manual amendments 

No. Page Description Date 

1 0.3, 0.6, 0.10, 1.11, 8.2, 

diagrams 5a, 11d, 8EP210 

ÄM 800-17-07 Fin tank valve and operating handle, Refuelling pump 

April 2007

2 0.3, 0.4, 0.6, 0.7, 0.10, 

0.12, 1.28, 1.29, 2.7, 3.3, 3.5, 3.11, 4.2, 4.8, 4.11, encl. 2 page 1, TN 4600-2-2 Solo 

TN800/34 Manual revision 

September 2007 

3 0.6, 8.1, diagram 10 TN800/35 

Extension-retraction unit, rear fork of spindle-drive 

April 2009
DG-808C 

0.2

ly left blank. 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 0.30.2 List of effective pages 

Section page issued replaced/ replaced/ replaced/ 0 0.0 June 2005 

 0.1 see manual amendments  0.2 "  0.3 "  0.4 "  0.5 "  0.6 "  0.7 June 2005 Sept. 2007 

0.8 " 0.9 " 

 0.10 " Sept. 2007 

0.11 " 

 0.12 " Sept. 2007 1 1.1 June 2005 

1.2 " 1.3 " 1.4 " 1.5 " 1.6 " 1.7 " 1.8 " 1.9 " 

1.10 " 

 1.11 " April 2007 

1.12 " 1.13 " 1.14 " 1.15 " 1.16 " 1.17 " 1.18 " 1.19 " 1.20 " 1.21 " 1.22 " 1.23 " 1.24 " 1.25 " 
DG-808C 

0.4

/ replaced/ replaced/ 

7 7 7 

7 

7 7 

7 

Maintenance Manual DG-808C 

Issued: June 2005 0.50.2 List of effective pages (continued)

Section page issued replaced/ replaced/ replaced/  4.17 June 2005 

4.18 " 4.19 " 4.20 " 4.21 " 4.22 " 4.23 " 4.24 " 4.25 " 4.26 " 4.27 " 4.28 " 4.29 " 4.30 " 4.31 " 4.32 " 4.33 " 4.34 " 4.35 " 4.36 " 4.37 " 4.38 " 4.39 " 

5 5.1 June 2005 

5.2 " 

6 6.1 June 2005 

6.2 " 6.3 " 

7 7.1 June 2005 

7.2 June 2005 

8 8.1 June 2005 

" 8.2 " 

 8.3 "  8.4 " 

9 9.1 June 2005  9.2 " 
DG-808C 

0.6

replaced/ replaced/ 

om 8-373 on 

 

om 8-373 on 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 0.70.4 List of content 

page 

0 General 0.1

0.1 Manual amendments .............................................................................. 0.10.2 List of effective pages............................................................................ 0.30.3 List of content ........................................................................................ 0.70.4 Airworthiness limitations..................................................................... 0.11

1 System description and adjustment data 1.1

1.1 Wing and tailplane setting data.............................................................. 1.11.2 Elevator control and trim system ........................................................... 1.21.3 Rudder control........................................................................................ 1.51.4 Aileron and wing flap control................................................................ 1.61.5 Airbrake control, wheelbrake................................................................. 1.81.6 Undercarriage......................................................................................... 1.91.7 Tow hooks............................................................................................ 1.101.8 Water ballast system ............................................................................ 1.111.9 Massbalance and weights of control surfaces...................................... 1.121.10 Fore and aft play of the wings.......................................................... 1.131.11 Power Plant ...................................................................................... 1.141.12 Retraction - Extension Mechanism.................................................. 1.171.13 Fuel system ...................................................................................... 1.181.14 Electrical system .............................................................................. 1.23 

1.15 Pitot and static system 1.29 
DG-808C 

0.8

2.1

................................................. 2.1

................................................. 2.1

................................................. 2.3

vice time ................................. 2.6

................................................. 2.7

3.1

................................................. 3.1

................................................. 3.2

................................................. 3.3

................................................. 3.4

................................................. 3.5

cing work 4.1

ssic)......................................... 4.1

................................................. 4.2

l circuit..................................... 4.2

arriage (main wheel)................ 4.3

y............................................... 4.6

ns ............................................. 4.7

................................................. 4.8

aperons .................................. 4.12

bing........................................ 4.13

............................................... 4.13

Maintenance Manual DG-808C 

Issued: June 2005 0.9

4.11 Replacement of wing fuel tanks (Option)........................................ 4.14

4.12 Mounting and tensioning of the drive belt....................................... 4.154.13 Replacing the bearings of the upper drive belt pulley ..................... 4.184.14 Removal and installation of the tension gas-strut............................ 4.204.15 Replacement of the engine retaining cable...................................... 4.214.16 Filling and bleeding the cooling system .......................................... 4.224.17 Installation and removal of the powerplant ..................................... 4.244.18 Removal and assembly of the engine doors..................................... 4.314.19 Securing the propeller bolts ............................................................. 4.324.20 Checking the Ignition unit type Ducati............................................ 4.334.21 Installation and removal of the extension/retraction unit ................ 4.364.22 Calibration of the fuel display in the DEI-NT ................................. 4.374.23 Further DEI-NT settings .................................................................. 4.37

5 Weight and balance 5.16 Instrumentation and accessories list 6.17 List of special tools 7.18 Partlist 8.1

8.1 Parts for the powerplant......................................................................... 8.18.2 Parts for the electrical system ................................................................ 8.38.3 Control surface sealings and turbulators................................................ 8.4

9 Enclosures 9.1

9.1 Equipment list ........................................................................................ 9.19.2 Checklist for checks and maintenance work.......................................... 9.2 
DG-808C 

0.10

 circuits, fuselage side 

wing side 

er. no. 8-373 on 

with electromagnetic valves 

ulley 

topper Option BBSA clutch 

moment of the flaperons 

y 

sion 

y Option BBSA clutch 

selage side with electromagnetic 

tion electronic boxes 

d service data from the DEI-NT 

on 

utch on the engines 2 625 01 and 2 

Maintenance Manual DG-808C 

Issued: June 2005 0.110.5 Airworthiness limitations 

0.5.1 Repairs Repair or replace damaged parts prior to next flight. Follow the instructions of the DG-800B repair manual for repairs of the airframe. Repairs outside the scope of DG-800B repair manual and major repairs must be accomplished at a certified repair station or by a certified mechanic rated for composite aircraft structure work in accordance with DG repair methods. Use only genuine spare parts. 0.5.2 Life time of the airframe The maximum allowable operating time for composite sailplanes is 12000 flight hours. Therefore inspections according to section 2.4 of this manual have to be executed at 3000 h, 6000 h, 9000 h and every 1000 hours following thereafter. 0.5.3 Life time of components a) The following components of the power plant have to be replaced after 

400 engine hours. 1. All nuts and bolts on the engine 2. The bearings of the upper drive belt pulley 

b) The gasket for the drainer valve has to be exchanged after 6 years. 

c) The hoses of the cooling system have to be ex-changed after 6 years. 

d) The 2 upper rollers for the drive belt have to be exchanged every 50 engine 

hours 

e) Drive belt: 

Without optional BBSA friction/centrifugal clutch: The drive belt has to be exchanged after 50 engine hours. With optional BBSA friction/centrifugal clutch: The drive belt has to be exchanged after 100 engine hours 

f) The spark plugs have to be exchanged after 25 engine hours. g) The fabric straps of the safety harness have to be exchanged after 12 

years. 

h) Other components 

All other components like tow hook, wheels, gas struts, control system parts, bolts, pins etc. have no life time limitation, but should be replaced when worn, damaged or disqualified by excessive corrosion. 

i) Flexible fuel bags in the wings (option) 

Type Uniroyal (rubber): these will have to be exchanged after 10 years. 
DG-808C 

0.12

ts 

facturer: 

 

turer. 

he manufacturer. 

r 

enance manual No. P3. 

anual section 8.8. 

 FAA approved and specifies 

.403 of the Federal Aviation 

een FAA approved. 

LBA approved 

Maintenance Manual DG-808C 

Issued: June 2005 1.1

1 System description and adjustment data 1.1 Wing and tailplane setting data 

Wing: Sweep back (Leading edge): 0 + 3 mm (+ 0.12 in.) at wing taper change 

Dihedral (Leading edge line): 2.5° = 196 mm (7.72 in.) at wing taper 

change (y = 4.5 m) 

Angles of Incidence: -1° measured at wing flap setting -5° Horizontal tailplane: -3,5° 

chord lines 

fuselage centre line 

(corresponding to boom slope 1000:37) 

Wing oscillation frequency: 

approx. 160/min 15 m span with winglets 

 approx. 130/min 18 m span without parting  approx. 124/min 18 m span with parting and 

winglets 

Aircraft should rest on both wheels during frequency measurements. 

1° 3,5° 
DG-808C 

1.2

.81 + 0.08 in. .81 + 0.08 in. 

xis which is directly at the edge 

or. Deflect the elevator to neutral 

line with the upper end of the fin. 

p and down displacement. 

loor

46±2 mm 

46±2 mm

Maintenance Manual DG-808C 

Issued: June 2005 1.31.2.3 Elevator stops The elevator stops are located at the base of the control column and can be adjusted with a 10 mm open ended spanner. 1.2.4 Elevator control circuit free play With the elevator held fixed at the 0 point, the free play at the top of the control column can be +1.5 mm (+0.06 in.). Within the automatic elevator connection 

there should be no free play noticeable when the elevator is moved at its trailing edge. Any free play can be reduced by screwing in the adjustment screw on the automatic connector funnel.

1.2.5 Trim 

The automatic trim mechanism should be adjusted according to the sketch below. The measurements a and b are with the control stick in forward position: a = 30 mm (1.18 in.), b = 187 mm (7.36 in.), c = 357 mm (14.1 in.). 

The bungee interconnection between wing flap lever 8S 9 and trim lever 2St32 is to be replaced, when worn or when elongated. The length in unstretched condition y must be 110 mm (4.3 in.). The interconnection consists of 2 mm diameter. bungee wound around 3 times. 

locking nut adjustment screw 

elevator 

y 

6St9 

2St32 2St32 a b 

c 

bulkhead 
DG-808C 

1.4

nism Bowden cable 

ble being installed, it should be 

ween the two parallel arms of the 

the sketch. 

le passes outside the mechanism 

 column movement can be 

d. 

Maintenance Manual DG-808C 

Issued: June 2005 1.51.3 Rudder control 

1.3.1 Rudder control circuit see diagram 2 1.3.2 Rudder deflections and tolerances 155mm (6.5 inch) (28°) +0, -5mm (-.2 inch) measured at 318 mm (12.52 inch) from the hinge axis. 1.3.3 Rudder stops The rudder stops are located at the lower hinge pedestal and can be adjusted with an Allen key wrench. 1.3.4 Axial free PlayThe maximum allowable free play at the upper hinge point is 1.5 mm (0.06 inch) 1.3.5 Sealing the rudder The rudder is sealed on both sides. On the outside with Mylar combi-tape and inside the fin with V-sealing tapes These sealings are not to be removed. If damaged it should be replaced, see section 4.7.5 

max. 1,5 mm 
DG-808C 

1.6

tional aileron return force at 

m 3 must not be greased (Teflon 

± 3 mm 1.65 + 0.12 in. 

± 3 mm 0.83 + 0.12 in. 

(at inboard end), wing flap 

± 3 mm (-0.75 + 0.12 in.) 

± 3 mm +1.50 + 0.12 in.) 

against the fixed part at the wing 

usted against the fixed part at the 

able left-hand side panel. The 

d with two 4 mm (5/32 in.) 

6St8. 

r at pushrod 6St8 with 

ment by displacing pushrod 6St8 

ich stops at the leaf-spring 8St4. 

e of the flaperons measured at 

ceed +1 mm (+0.04 in.) The 

tral position. 

posite wing. With both flaperons 

 in.) at the top of the control stick 

Maintenance Manual DG-808C 

Issued: June 2005 1.71.4.5 Complete readjustment Should it be necessary to completely reset the flap and aileron control, proceed as follows: Place the fuselage with the centre line horizontal see sect. 1.1. Fix the mixer shaft 8St70 (see diagram 3) in horizontal position.

then: 1. Adjust the control stick to neutral. 2. Adjust the wing flap handle to 0° flapsetting. 3. Adjust the flaperons: + 10.6 mm (0.42 in.) measured against the fixed part at the wing root and + 4.1 mm (0.16 in.) against the 18 m wing tip. To adjust the flaperons you must first remove the fairings from the control surface horns. Then unscrew the horns (Allen key wrench) and loosen the lock nut (12 mm open ended wrench) at the rod ends. Adjustment is made by rotating the complete drive. Note: Secure the bolts again with a small amount of Loctite 243. 4. Adjust the aileron stops. (See 1.4.3) 5. Check the flap deflections and adjust the stops if necessary. (See 1.4.3) 6. Glue the fairings to the control surface horns with Polyester resin. Apply pressure when gluing to prevent the fairings interfering. 

horizontal 

8St70 
DG-808C 

1.8

ake torsion shaft (part 8St12). 

he airbrake rod in the airbrake 

d that the overcentre locking 

tween 15 - 20 daN (33-44 lbs.). 

 end spanner. 

irbrakes extend depends on the 

ct, the wheel- brake can be 

den cable housing, located on the 

 actuating lever. 

turnbuckle between main brake 

that with the airbrakes fully 

ad) the wing flap handle will be 

e +5° notch. Adjustment at the 

. 

 at the seat back bulkhead. The 

r adjustment, see above. The 

 rootribs. The corresponding stop 

e placed to allow a free play of 0-

nd the stop at the guide rod with 

o effect. 

d not have so much free play that 

o their boxes during retraction 

Maintenance Manual DG-808C 

Issued: June 2005 1.91.6 Undercarriage 

1.6.1 Main undercarriage 

1.6.1.1 Undercarriage control circuit see diagram 15, undercarriage see 

diagram 16 

1.6.1.2 Adjustment 

a) Should the undercarriage not retract fully, an adjustment can be made 

by screwing out the universal rod end on pushrod 8FW47 with a 13 mm open end spanner. 

b) The lock, in extended position, is by means of the gas strut on the 

landing gear box and additionally by a locking rubber buffer in the cockpit. The clearance between the locking latch at the handle and the front end of the rubber buffer should be 0.5 to max. 1 mm (.02 to max. .04 in.) with the spring suspension of the undercarriage fully extended. Adjustment can be made at the mounting of the rubber buffer. A torsion-spring is installed to keep the handle in the locked position. 

1.6.1.3 Free play 

Free play between lever 8FW42 and the upper strut 8FW40/1 is not allowed. If there is any free play, the two securing bolts M 6x40 should be tightened with a 10 mm open end spanner. If there is still some free play, the bolts should be removed and the holes drilled out and reamed to diameter 8 H7. M 8x40 LN 9037 bolts should then be installed. 

1.6.2 Tailwheel 1.6.2.1 The steerable tailwheel is connected to the rudder via two tension 

springs, the tailwheel-fork is mounted on needle bearings, see diagram 12a. 

1.6.2.2 Disassembly of the tailwheel fork 

1. Remove the tailwheel 2. Loosen the M 5 nut (8mm spanner) 3. Release the springs 4. Draw the fork out while displacing it sidewards. 

1.6.2.3 The tailwheel axle must always be fixed tight. 1.6.3 Tyre pressure 

main wheel 3 bar 43 psi 

tail wheel 2 bar 29 psi 
DG-808C 

1.10

ace between the tow release knob 

e bent or ground down and move 

e has to be exchanged and 

rection (use a piece of hard wood 

he seat shell with the C.G. tow 

tions 

nd maintenance instructions for 

aintenance manual) 

Maintenance Manual DG-808C 

Issued: April 2007 ÄM 800-17-07 1.111.8 Water ballast system 

1.8.1 Water ballast release circuit 

see diagram 5 

1.8.2 Wing tanks Version DG-808C Classic: double wall bags with a capacity of 50l per wing. Version DG-808C Competition: double wall bags with a capacity of 60l (15.85 U.S. gal) or 75l (19.8 U.S. gal) per wing. The 75l waterbags are separated in 2 chambers. A check-valve is located between the 2 chambers. Operating the waterballast system without the check-valves is prohibited. a) Adjustment 

For the dump valve in the closed position, there should be 1 mm (.04 in.) space between the 8 mm (.315 in.) diameter PVC rod from the dump valve, and the plate lever on the fuselage. Adjust at the adjustment screw located at the fuselage wall. If this is insufficient, the 8 mm PVC rod can be shortened. If a valve still leaks, then the rubber gasket and the associated spring at the end of the 8mm PVC rod should be loosened, pressed further in and secured again. If this is not successful, the valve ball seat should be greased. (see sect. 4.1) 

b) Servicing 

see section 4.1. 

1.8.3 Fin tank (only version DG-808C Competition) The fin ballast tank is constructed as integral tank. a) Adjustment 

The release cable must be adjusted so that the cable just becomes loose when the handle is parallel to the fuselage wall. 

b) Inspection 

According to sect. 2.2 a special inspection is to be carried out on the fin ballast tank system at each annual inspection. The dump time of the full fin tank should be timed and should not exceed 120 seconds. Check the calibration of the outside air temperature gauge (in the DEI-NT). Up to ser.no. 8-372: Remove the tailwheel and the cover plate in the tailwheel box. Check the control cable and the lever of the valve carefully for wear. Check the control cable at the operating handle too. If the cable or the lever is worn, further use of the fin tank is prohibited. Please contact the manufacturer for a detailed repair instruction. From ser. no. 8-373 on: Check the control cable at the operating handle and at the dump valve (installed in the lower rudder mounting bracket). If the cable is worn, further use of the fin tank is prohibited. 
DG-808C 

1.12

faces 

rfaces weights and moments 

 Spring balance 

reading see 

instructions below

kg 

(lbs.) 

min. max. min. 

12 0.225 0.156 

2.71) (0.495) (0.343) 

.08 0.293 0.230 

2.67) (0.646) (0.507) 

.27 0.900 0.760 

8.05) (1.984) (1.676) 

.66 0.850 0.710 

7.52) (1.874) (1.566) 

.55 0.105 0.083 

0.48) (0.231) (0.183) 

weights are made, contact the DG 

ments 

ce and hang it friction free on two 

ositioned upside up. 

4.8. 

int distance behind 

hinge line (mm) 

200 7.9 in. 

mm 

134 5.3 in. 

122 4.8 in. 

66 2.6 in. 

Maintenance Manual DG-808C 

Issued: June 2005 1.131.10 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. 

c) Screw out the lift pin and insert a distance washer (inside diameter 

16.5 mm(.65 in.)) and screw in the pin again. Tighten the lift pin. 

d) Rig again and check the free play. 

1.10.2 At the wing tip joint (option)a) Check see above. b) Roughen the area around the lift pin and attach a distance washer inside 

diameter 10.5 mm (.41 in.) 0.25 mm (0.01 in.) thick with a suitable metal adhesive (e.g. Stabilit Express). Note the total thickness of the washers at the root rib with a waterproof marker pen. 

c) Rig the wing tips again and check the free play. 1.10.3 TolerancesFree play should be adjusted if you hear a rattling sound when moving the wings backwards and forwards. The max. amount of free play can also be determined as follows: Measure the free play at each lift pin with a feeler gauge. Sum up the free play. At fuselage: The free play of all 4 pins together should not exceed 0.5 mm. At the wing tip joint: The free play of the 2 pins together should not exceed 0.5 mm. 
DG-808C 

1.14

nations and the reference 

e end of this manual. 

lectronic dual ignition and liquid 

ons refer to the engine manual, 

ng circuit is equipped with an 

es with ignition on. If the glider 

ch) with running engine, the 

from the generator. 

led water (up to approx. –40°C, 

ne for periods longer than 2 

e according to the instructions in 

for any overseas transportation. 

ed for the DG-800B and is 

movable frame, secured with 

olts: - six M 8 x 65 DIN 931 - 

ole for lockwiring. Tightening 

8 ft lb). 

nal BBSA friction-centrifugal 

ler stop in a vertical position 

positioned accordingly to the 

 the propeller in the position for 

be in the following position: 

view from the rear

x 

Maintenance Manual DG-808C 

Issued: June 2005 1.151.11.5 Drive Belt: 

Type of drive belt see section 8.1. Drive Belt Tensioning: The drive belt should not be loose. Tensioning adjustment can be made by turning the eccentric propeller shaft, see sect. 4.12g. As Option a BBSA friction-centrifugal clutch may be installed to reduce the drive belt loads when starting the engine. The clutch is maintenance free and constructed as one unit together with the lower pulley and the starter ring gear. With the clutch the propeller position to the compression point of the engine will change every engine start, so for aligning the propeller for retraction a stopper according to drawing 8M234 (enclosed to the MM) is necessary. 

1.11.6 Starter: 

Electric starter motor, type see section 8.1. 

1.11.7 Ignition system: 

a) spark plugs;

Electrode gap 0.5 mm (o.02 in.). Type see section 8.1. 

c) The electronic boxes (incl. ignition coils) are mounted at the propeller 

mount (carbonfibre tower). 

1.11.8 Throttle cable connections 

The cable can be finely adjusted at the connection point just below the carburettor. With fully open throttle (butterfly valve vertical) the cable should be loose. The cable is 1.5 mm diameter Bowden-cable Friction device for throttle control: This device is located at the control bellcrank in the instrument panel. The brake force must be adjusted for a control force of 15 - 50 N (3 - 11 lbs.). 

1.11.9 Propeller brake 

see diagram 13 a) manual activation: The brake cable can be adjusted at the 

adjustment screw at the rear end of the engine. 
DG-808C 

1.16

 electric brake-motor acts on the 

milar to the manual brake and via 

 directly at the brake motor 

 side of the engine bay. 

learance of at least 0.5 mm 

magneto flywheel. The brake pad 

3 mm (.1 in) of pad left. The pad 

0. The glue must be cured for min. 

ment pads: part no. 8M275/3. 

 bracket: part no. 8M287/3. The 

h Loctite 243. 

secured by selflocking nuts 

ollowing: 

40 N m ( 29 ft lb) 

20 N m ( 15 ft lb) 

12 N m ( 9 ft lb) 

tite 243. All locked and secured 

 also marks the respective 

henever a bolt has to be tightened 

be removed and only renewed 

tached with Loctite. 

20 N m (15 ft lb) 

15 N m (11 ft lb) 

20 N m (15 ft lb) 

20 N m (15 ft lb) 

80 N m (58 ft lb) 

100 N m (73 ft lb) 

 side wall opposite to the 

he „fire“ probe in the wiring near 

ion is installed. 

he fire warning light must flash 

Maintenance Manual DG-808C 

Issued: June 2005 1.171.12 Retraction - Extension Mechanism 

1.12.1 Layout see diagram 10 1.12.2 The retraction-extension mechanism 

(spindle drive) consists of a 12 V electrically driven sealed trapezoid screw shaft. A tension gas-strut is installed parallel to the spindle drive to compensate the engine weight. 

1.12.3 Extension force of the gas-strut 

Time for extension approx. 11-13 seconds, time for retraction approx. 10-12 seconds. If the extension takes much longer (4 seconds) then the gas-strut must be replaced. Measure at room temperature, with full batteries and via the ignition switch. 

1.12.4 Adjusting the powerplant retaining cable 

Extend the engine via the ignition switch until the extension is switched off by the position switch. It should be possible in this position to pull out the retaining cable approx. 15mm (.6 in.) before it comes to its stop. If necessary adjust via the adjustment screw. Secure the adjustment screw by fastening its lock nut.

1.12.5 Position switches 

Position engine retracted: via a switch actuated by the propellermount Position engine extended: via a switch actuated by the muffler frame 

1.12.6 Adjustment of the powerplant positions 

Position engine extended for operation: Extend the engine via the ignition switch until the extension is switched off by the position switch. The angle α must be 91°. If necessary, the angle has to be corrected by bending the metal lever of the limit switch. 

α

propeller mount

edge of engine bay 
DG-808C 

1.18

tch. When the propellermount 

he propellermount) the 

ff, but should move the 

m (.2 in.) before the position 

owerplant from moving upwards 

e rubber mounts). 

d and has 21 litres (5.55 US gal.) 

t least 0.5 l (0.13 US gal.). The 

ed in the landing gear box at its 

r removing the drainer. The vent 

tom of the fuselage. 

in the wings, see section 1.13.9. 

 content of the bag can be drained 

with the installed electric 

filler) switches off the electric 

 is filled completely and 

f the fuel gauge. 

er opening on the fuselage 

tion will be executed. A manual 

al section 4.2.3.3. 

 line with built in restriction 

k. 

Maintenance Manual DG-808C 

Issued: June 2005 1.19

1.13.3 Fuel pumps 

Electric fuel pump mounted in the fuselage centre section. This pump operates as soon as the ignition is switched on. In case the electric power is switched off via the master switch with running engine, the pump will receive electric power directly from the generator. Min. fuel flow at the electric pump: 40 l / hour (10.6 U.S.gal. /hour). The fuel flow can be determined by disassembling the fuel supply line at the distributor near the carburettor and flowing 1 litre (.26 U.S.gal.) of fuel into a container. Max. time for 1 litre: 90 seconds. (The fuselagetank should contain at least 10 l (2.6 U.S. gal.) of fuel for the measurement). Should the flow rate be lower, then the filter could be dirty or there could be an obstruction elsewhere in the fuel system. In line to the pump described above, a second pump is installed. This pump receives its electric power only from the generator, so it operates only with the engine running. It is protected by a separate fuse located in the control unit, so that this pump operates even with the main switch off. Via a press button located in the instrument panel, the first pump can be switched off with the engine running to check the function of the second pump. The excess fuel line with built in restriction limits the fuel pressure . 

1.13.4 Fuel cock 

The fuel cock is mounted on the fuselage floor between the tank and the electric fuel pump. The cock is controlled by a diameter 2 mm (0.08 in.) piano-wire from the cockpit. The stops are located directly at the lever of the fuel cock. 

1.13.5 Fuel filter 

The filter is installed between fuel cock and electric fuel pump. The filter is visible in the baggage compartment. Warning: Use only a transparent filter, type see section 8.1. 

1.13.6 Fuel quantity indication 

The fuel quantity measuring system in the fuselage tank is by condenser plates. The aircraft's attitude hardly affects the readout. Incorrect readings can result if the condenser plates are dirty. A thorough flushing of the plates and fuel tank should solve the problem. As different fuel qualities may result in different readings a calibration should be carried out each time the tank is filled completely, see sect. 1.13.2.3. After replacement of the DEI-NT you have to execute a complete fuel gauge calibration according to sect. 4.22. 
DG-808C 

1.20

mer) is installed. 

t nozzle is fully anticlockwise 

 nozzle may be turned in 

xecute items 1 to 3. Switch on the 

 electric fuel pump. 

 will spurt out. In addition, the 

e to be cleaned with compressed 

 actuates the needle valve. 

w the carburettor cover and 

Loosen the mounting screw and 

ve as one unit. Be careful not to 

Maintenance Manual DG-808C 

Issued: June 2005 1.21

2. Removal of the main nozzle:

Loosen the 2 screws and lift off the cover plate with the rubber sealing Screw out the main nozzle. If it is necessary to remove the Tommy screw for cleaning you have to lift off the fine adjustment screw which covers the Tommy screw. Screw in the Tommy screw first to note the number of turns. 

3. Removal of the idle nozzle:

Screw in the Tommy screw first to note the number of turns and the actual position of the lever ( 1 1/8 turn). Then turn out the Tommy screw. In addition to the Tommy screw an idle nozzle must be screwed out.The nozzle is located in the same compartment as the main nozzle below the main nozzle. 

4. Reassembling:

Screw in the Tommy screw(s) completely and then screw them out to the noted positions. The membrane is to be positioned between the rubber and the metal cover plate. Use Loctite 243 to secure the screws of the carburettor cover. All measures should be executed carefully and cleanly. 

5. Carburettor setting:

Adjust the idle RPM by the idle adjustment screw to approx. 2500 RPM with warm engine. Note: With optional EGT probes the setting of the carburettor main nozzles can be controlled by the EGT values. Set the nozzles to EGT values of 640°C + 10°C on the ground at full power with the engine 

warmed up. This value is valid with the fine adjustment screw open and for the hotter of both cylinders at 100m above MSL. If the adjustment is to be done at a higher altitude 2.5°C must be deducted from the EGT value per 100m altitude. 

1.13.7.3 Intake air filter 

An airfilter is mounted on the carburettor. Operation without air filter is prohibited except for conservation of the engine see engine manual section 5. 
DG-808C 

1.22

ection system for engine start 

alve. The injection valve is 

arburettor. 

he electric fuel pump. Via a 

mer can be switched off or to 

unit controls the amount of fuel 

emperature. 

ll be injected and injection 

 the cold engine from stopping. 

nt will be injected in pulses 

hot engine nothing will be 

ge on the centre display as long 

 primer see section 4.23. 

on) 

t in the wings. 

4.10. 

hould be stored at temperatures of 

ative humidity of 50-70%. 

light and should not be stored 

mptied completely but contain at 

in engine oil (e.g. SAE 10) 

r any wear or cuts. Be careful not 

wings, they should not be emptied 

 

Maintenance Manual DG-808C 

Issued: June 2005 1.231.14 Electrical system 

Note: Before doing any work on the electrical system, isolate the power supply by switching off the main switch. The batteries should also be disconnected before working in the relay compartment. This is done by disconnecting the red cable marked with a black ring from the fuse terminal. See the sketch below.

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. 

1.14.1 Layout

see wiring scheme and wiring plan enclosed to this manual. 

1.14.2 Batteries 

• The installed battery-pack consist of 4 batteries 6V 10 or 12 Ah with 

screwed terminals. The batteries are wired in series and parallel to supply 12V/20 or 24Ah. The two 12V packs (wired parallel) are protected by fuses against discharging each other when defective and against over current. 

• The batteries are charged by a generator installed in the engine. • Recharging is via the socket 12 V in the main bulkhead. Therefore 

switch on the main switch. to the first (charging) position. You don't need to remove the batteries for charging. 

• Warning: Use only automatic chargers suitable for sealed liquid acid 

batteries. 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. 

disconnect this cable

battery fuses 

instrument console

direction of flight 
DG-808C 

1.24

elay compartment. The control 

ons: 

 procedure. The extension

 inside the unit. 

 power to the fuel- and coolant

motor is actuated by a power 

to the normal engine start 

ning of the propeller into 

Activation is via the starter 

led in the control unit see section 

ct the power plug first when 

power plug after the other plugs 

ctor plugs, carefully fix the plugs 

ar housing and is incorporated 

connected to a voltage regulator 

 current of 10 Amp. The regulator 

1.14.3. The generator supplies 

pumps, even with the master 

switch (no separate engine master 

 on position electrical power to 

witch located in the console below 

controls a relay in the control unit 

Maintenance Manual DG-808C 

Issued: June 2005 1.25

1.14.6 Engine elapsed - time indicator: 

The engine time indicator is incorporated in the DEI-NT and counts as soon as the proximity switch detects that the propeller is turning and therefore counts only the pure engine running time. 

In addition the time to the next 25 hour maintenance will be displayed. When the maintenance has been executed, this time must be reset to zero in the DEI-NT set up menu. 

1.14.7 Electric pumps: 

First fuel pump: Power supply from the batteries and from the generator (protection via a re-settable fuse in the control unit). Coolant pump: Power supply from the batteries and with the engine running directly from the generator (protection via a re-settable fuse in the control unit). Second fuel pump: Power supply only with the engine running directly from the generator (protection via a re-settable fuse in the control unit) 

1.14.8 12 V Socket: 

The socket is located in the fuselage main-bulkhead (behind the pilots left shoulder). It is used for: 

- battery charging (main switch in charging position) - to provide power for external accessories (main switch “on”). 

Required plug see sect. 8.2. Connection of the socket terminals: centre pin is positive. 

1.14.9 Power plant extension-retraction mechanism: 

See also sect. 1.12 The automatic extension and retraction is controlled by the control unit see sect. 1.14.3. The extension-retraction motor will be switched off at the end limits by position switches see sect. 1.12.5. Caution: If the proximity switch (see sect. 1.14.15) is defective (short circuit) a safety interlock in the control unit prevents the engine from being retracted automatically with the propeller not in the correct position. The retraction of the powerplant must be done with the manual switch. The DEI-NT will display the failure message “RPM Pickup”. The proximity switch must be exchanged prior to the next engine start. 
DG-808C 

1.26

 

 one switch which is located on 

h is operated, the automatic 

itched off. The automatic system 

perate the ignition switch. The 

/retraction relays in the control 

he centre of the throttle handle 

rter relay in the control unit, see 

ng plan 8E250 at the end of the 

rcles at their ends. 

AWG mm2 

6 13 

8 8 

10 6 14 2 

16 1,3 18 0,9 22 0,4 

22 0,4 with shielding 2x22 2x0,4 with shielding 

with shielding 

2x24 2x0,22 NiCrNi with 

shielding 

4x0,25 with shielding 

18 1 high flexible 

wires located at the engine 

cations mentioned above suitable 

ther aircraft or MIL specifications 

5°C up to 105°C (-67°F up to 

p to 150°C (300°F), operating 

Maintenance Manual DG-808C 

Issued: June 2005 1.271.14.13 Circuit breakers and fuses 

1. In the console of the instrument panel: 

a) circuit breaker 2 A for electric variometers etc. b) circuit breaker 3 A for the radio c) 3A for turn and bank or artificial horizon d) circuit breaker 3 A spare eg. for the transponder 

2. The battery main fuses are located in the seat shell at the right hand side 

of the instrument panel: 2 pieces 60 A. 

3. Fuse 250V 0.2A 5x20 m for the fire warning light located in the wiring 

near the master switch. 

4. Resettable fuses are installed in the DEI-NT unit for the following 

circuits: Tankoscillator 0,2A Alarm outlet 2 fuses 0,2A Change over switch when extending the powerplant 0,2A e.g. for a Headset. 

5. In the control unit: 

Resettable fuses are protecting the following circuits: a) DEI-NT 0.4A b) Proximity switch 0.2A, c) Engine extension-retraction motor 10 A d) full tank sensor 0,05A e) 12 V socket 4 A f) bug wipers 7A and a safety fuse for the Generator 15A The following circuits are protected by their semiconductor switches: a) Fuel pump 1 b) Fuel pump 2 c) Coolant pump d) Refuelling pump e) Propeller brake motor 

1.14.14 Position switches for the powerplant 

see sect. 1.12.5 and 1.12.6. 
DG-808C 

1.28

ceives the switching pulses by the 

lt pulley, see drawing 8M110 at 

wing functions: 

nism and indication in the DEI

e propeller can't hit the engine 

 moved (distance to the steel pins 

measurement won’t work 

hing the control light at the rear 

splay (main switch on). 

ance of 1.8mm (.071 in.). 

switch with the 4 counter nuts, as 

M measurement and the 

ort circuit) the failure message 

e DEI-NT. 

utton located in the fuselage 

shoulder). As soon as the fuselage 

ally switches off the pump. If you 

procedure before the tank is full 

he pumping again is only possible 

 unit. 

nd engine 

nd earth wires all wires can be 

he hinge of the powerplant (at the 

e engine compartment) to 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 1.291.14.18 DEI NT= (Digital Engine Indicator) 

For a description of the readouts and the various functions and the set up menu see flight manual sect. 7.4. The DEI-NT controls all functions together with the control unit see section 1.14.3. - The RPM measurement is fully digital and counts the impulses of 

the proximity switch. 

- The coolant temperature (CHT) is measured by a temperature probe 

which is screwed into the coolant circuit in the rear cylinderhead. 

- Fuel level measurement see sect. 1.13.6. FunctionsThe following functions are controlled by the DEI-NT: a) by the ignition switch - the ignition (shorting of the magneto coils) - with the ignition switched off the engine automatic retraction and 

the control of the propeller position and propellerbrake will be activated. 

- with the ignition switched on the electric fuel pump, coolant pump, 

the automatic extension of the engine and the control of the starter motor will be activated. 

b) the RPM indicator controls a relay which prevents the starter motor 

working whilst the engine is running. 

c) the limit switch see sect. 1.12.5 at the engine mount activates the 

control of the starter motor only when the engine is extended 

d) the proximity switch see 1.14.15 prevents the automatic retraction 

of the engine as long as the propeller is not in the correct position for retraction (with the manual extension-retraction switch see sect. 1.14.10 not operated). 

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. Warning: with the connector plug disconnected from the DEI-NT, the ignition is not short-circuit. This means the ignition is on. Don't turn the propeller! 

1.15 Pitot and static system 

1.15.1 Layout 

see diagram 6 

1.15.2 Maintenance 

No special maintenance needed. 
DG-808C 

2.1

nual inspection

y around the S tubes on the rudder 

ced (see section 4.2. 

n 1.3.5. 

e flight manual section 4.3. 

devices ie. locknuts, split pins etc. 

and rust prevention. (see section 

ections 1.2 up 1.4). 

ee section 1.2up to 1.6) 

e section 1.10). 

rding to section 7.14 of the flight 

 to section 1.8.3 

rol (see sect. 1.11.8). 

ect. 3.5.1. item 25 of this manual. 

e instructions for the release 

ce manual have to be followed. 

se should be checked at least 

 

Maintenance Manual DG-808C 

Issued: June 2005 2.2

C Every 3 months

Check the emergency canopy release according to flight manual sect. 7.12. Only version Classic: Check the tension of the lines of the waterbag attachment (see section 4.1). 

D Special inspections

Tow hook After a wheel up landing, the tow hook mechanism is to be carefully checked for any damage. After a landing where the fuselage nose has touched the ground, the nose tow hook (Option) is to be cleaned and to be checked for correct functioning. Clean the hole of the PC port (necessary for the stall warning) located behind the fuselage nose on the lower surface C.G. weighing: After all work which may influence the C.G. 
DG-808C 

2.3

igned in the vertical and 

g frequency with respect to 

eformation - are there any white 

oint or rib/spar joint? If so, 

ck continues into the structure. 

e airbrake housing and on the 

 are harmless, if these don't 

. 

drives checked? 

pin tubes, difficult assembly? 

of the fin try to turn the fin around 

excessive deformation? 

ng this torsion? 

Maintenance Manual DG-808C 

Issued: June 2005 2.4Fuselage - 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 glass fibre structure? Disassemble the rudder and check the glued connection of the fuselage end bulkhead and the fin trailing edge web. To check the elevator control circuit and the bulkhead attachments in the fin area, the tailwheel and the cover plate in the wheel box should be removed. When reassembling glue the cover plate with silicone. Tailplane attachment:Increased free play? Cracks in the fin top rib, fin sparend with tailplane attachment, especially around the bushes? Rudder mounts:Increased free play? White areas in the glass fibre, bent rudder hinge pin supports? Fuselage skin:outside: cracks, nicks, folds? inside: white spots, zig zag white lines, cracks? Has any bulkhead become loose? Tow release:Especially after a wheel up landing, check for dirt etc., check for proper functioning. Has the tow release housing become detached from the fuselage? Front main bulkhead:Cracks? Shoulder strap attachment point? Belly harness attachment points:Check for cracking around the mountings in the seat and excessive free play. Controls:Check for proper functioning and condition of all controls and adjustment mechanisms (i.e. rudder pedal adjustment, tow release, air brake, control column and trim etc.). 
DG-808C 

2.5

n the pitot probe? 

e retract without scratching the 

efore? 

tant paint. 

rks? Proper extension and 

emove the baggage area floor 

Undercarriage control circuit 

lever and rear upper fork? 

ment? 

rding to flight manual section 4.3. 

Maintenance Manual DG-808C 

Issued: June 2005 2.62.4 Inspection procedure for increase of service time 

1. General

The results of fatigue tests of wingspar sections have demonstrated that the service time of GFRP/CFRP gliders and motorgliders may be limited to 12000 hours, if for each individual glider (in addition to the obligatory annual inspections) the airworthiness is demonstrated according to a special multi-step inspection program particularly with regard to the service life. 

2. Dates

When the glider has reached a service time of 3000 hours, an inspection must be done in accordance with the inspection program mentioned under point 3. If the results of this inspection are positive or if any defects found have been duly repaired, the service time of the glider is extended by another 3000 hours to a total of 6000 hours (first step). 

The above inspection program must be repeated when the glider has reached a service time of 6000 hours. If the results of this inspection are positive or if any defects found have been duly repaired, the service time of the glider is extended to 9000 hours (second step). When the glider has reached a service time of 9000 h the above inspection program must be repeated. If the results of the inspection are still positive, or if any defects found have been duly repaired, the service time may be extended to a total of 10000 hours (third step). Proceed analogous when reaching 11000 hours (4. step). 

3. Ask the manufacturer for the necessary inspection document. 

4. The inspection must only be done by the manufacturer or by a licensed 

repair station or inspector. 

5. The results of the inspections have to be recorded in an inspection test report 

wherein comments are required for each inspection instruction. If the inspections are done outside the manufacturer's facilities, a copy of the records must be sent to the manufacturer for his evaluation and information. 
DG-808C 

2.7

 the wing roots: 

oot rib. Insert a mirror with 

ccess hole. 

Maintenance Manual DG-808C 

Issued: June 2005 3.13 Maintenance 3.1 General maintenance 

See also flight manual section 8. Exterior surfaces of the fibre reinforced plastic parts The surfaces are coated by a UP-gelcoat or by PU paint (Option). This gelcoat is protected by a hard wax coating which has been applied during production with a rotating disc ("Schwabbel" procedure). Do not remove the wax, because this would lead to shading, swelling and cracking of the surface. In general, the wax coat is very resistant. As soon as the wax coat is damaged or worn, a new coat has to be applied. If you store your aircraft often outside, this may be necessary every half year! "Schwabbel" procedure: The best method is with an electric power buffer as we do in the factory. Also an electric drill may be used. Speed approximately 2000 RPM. Two packages of special cloth discs (Schwabbelscheiben) have to be installed. A block of hard wax has to be pressed against the rotating discs. 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. Wax Part-No. 70000121 Cloth disc Part-No. 70000600 You get the best effect when polishing 90° to the microscratches of the sanding process. Note: Make sure that the surface does not get too hot, otherwise the finish will be damaged. Therefore move the polishing machine all the time, and do not stay on one spot! 
DG-808C 

3.2

canopies can be removed by the 

canopies to the fuselage! 

 not surface protected and must 

 3.3). The other metal parts, 

uld be preserved with metal 

of the surfaces (see above) and 

ll pins (see section 3.3). 

e box and tow hook should be 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 3.33.3 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. • Airbrake drive connection - in airbrake box, also grease the brake paddle 

pivots. 

• Remove the access panel on the left hand cockpit wall and grease all the 

pushrod guides. 

• Remove the baggage compartment floors and open the baggage compartment 

rear cover to grease all bearings. 

• Remove the control column cover and grease all the bearings associated with 

the control column. 

• 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 flaperon, airbrake and elevator 

control. 

• Clean and grease all pins and bushes of the wing and tailplane attachment. • Take off the canopy and clean and grease the locking mechanism. After 

reinstalling the canopy, check the force needed for emergency release with the red handle, using a spring balance. The force should not exceed 200 N (44 lbs.). 

• Clean and grease the power plant 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). Use thin engine oil e.g. SAE 5W30. Note: The sliding guides of the following parts are made from Teflon and should not be greased: Airbrake control handle 6St9 on 6St15 see diagram 3 If these parts have been greased inadvertently you have to disassemble the parts and to clean them completely with Acetone. 
DG-808C 

3.4

riod of non-use, an inspection 

nges such as small holes, bubbles 

 signal that something may be 

ugzeugbau factory immediately 

m a licensed inspector or from an 

ation, the correct repair 

n the skin surfaces can be 

materials used in your aircraft can 

d or major fittings on the wings, 

e patches are noted around them 

ponent parts cannot be repaired 

nd alignment! 

aged areas to execute repairs! 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 3.53.5 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. Caution: With an optional BBSA slipping-centrifugal clutch installed to the engine refer to Solo technical note No. 4600-2-2 attached to this manual for servicing the clutch. 3.5.1 25 hour inspection Note: The engine time until the next maintenance is displayed on the DEI-NT operating time screen. After completion of the 25 hour inspection reset this time to zero, see section 4.23. The following checks and maintenance work should be done every 25 hours engine time. Items 1, 2, 3, 7, 8, 10, 13 and 26 should be executed at least 1 year after the last 25 hour inspection, preferably with the annual inspection. Checklists for this maintenance work are in the enclosures of this manual. Please complete the checklist when executing the inspection and file it in the aircraft log. 1. General visual inspection. 2. Change spark plugs. Check if the spark plug connectors have a tight fit on 

the spark plugs after you have exchanged the spark plugs. If not, the connector must be replaced. 

3. Exchange the fuel filter. Use only a transparent filter, type see section 8.1. 

Assembly see diagram 11c. 

4. Measure fuel flow (see sect. 1.13.3). Disconnect the hose at the T-junction 

behind the rear carburettor. Hold the hose into a measuring container. Switch on the electric fuel pump with the ignition switch. Determine the time for supplying 1 litre of fuel. For the measurement a minimum of 10 l of fuel should be in the fuselage tank. Note down the value, max. time is 90 seconds for 1 litre. 
DG-808C 

3.6

ne, remove the needle valve, flush 

mp. The fuel must spout out as a 

eaks out of the carburettor when 

t: 

 from closing completely. 

at the engine can't receive the 

ve to disassemble the main nozzle 

7.2 item 2. 

ble for damage and wear. 

 filter is installed in the fuel 

nserted. Loosen the hose clamps 

and pull out the primer. Flow fuel 

d check that as the fuel comes out 

on flow fuel in reverse direction 

ctor where the excess fuel line 

ector. 

nd nozzle (engine must be cold). 

n. Remove the air intake filter. 

rimer test Y, then switch on the 

w the DEI-NT must display a 

ust be injected via the nozzle into 

thout the starter motor operating. 

erwise you may flood the engine. 

 primer test N, otherwise the 

er valve to the carburettor for any 

nition on (fuel pump running) 

Maintenance Manual DG-808C 

Issued: June 2005 3.7

7. Check all fuel lines for any wear, kinks, tight fit and leaks. Check especially 

the fuel lines in the engine compartment, switch on the ignition to run the fuel pump. 

8. Check the intake airfilter of the carburettor for excessive dirt and wear, wash 

with pure petroleum spirit and blow compressed air in reverse direction through the filter. Spray the outside with oil for filters with cotton fabric, reinstall the filter. We recommend exchange of the filter every 25 hours. Also new filters must be sprayed with filter oil. 

9. Check all cables and associated levers and the propellerbrake (see sect. 

1.11.8 and 1.11.9). Replace levers and pins of the brake in case of excessive free play. Replace cables when worn. 

10. Clean engine and radiator 

11. Check cooling system for leaks, refill coolant if necessary, check antifreeze. 

Check the radiator and its mounting. To check the water pump, switch on the ignition. You should hear a buzz. 

12. Remove the exhaust manifold. 

Check the cylinders and pistons via the exhaust ports for seizing marks, for carbon remains and for sticking piston rings. Press against the piston rings with a suitable tool. The rings must be movable. Black remains on the outside of the pistons below the rings indicate sticking or damaged piston rings, this is not acceptable..

Illuminate the combustion chamber and check for combustion deposits. Use a torch and mirror for these checks. If seizing marks are detected the engine must not be used. Excessive combustion deposits have to be removed. With sticking piston rings the cylinders must be removed. Take out the piston rings and clean the grooves and the rings or replace the rings. Remove also any combustion deposits inside the pistons. Caution: Necessary repair work including removal of combustion deposits must be accomplished at a certified repair station rated for such engine work. 
DG-808C 

3.8

ounting is secure. Check 

during engine extension. 

fting cable incl. the rubber cord. 

the muffler for cracks. Check the 

cks. Reinstall the exhaust 

 the gaskets, install new gaskets. 

muffler frame. Therefore retract 

ds. The gas-spring must press the 

heck the length of the cable which 

 the engine and press the muffler 

nd with a force of approx. 5 daN 

ring in the cable has been 

rfere with the exhaust manifold. 

f exhaust manifold to muffler. To 

een the brackets for the spring 

vable part of the muffler in 

 the fully extended position. 

e approx. 1 mm (0.04 in.) smaller 

m (0.02 in.) you have to adjust to 

procedure you will pull the 

able part the difference should be 

ow breaking in of the parts. 

ue wrench (see sect. 1.11.10). 

y for cracks. Therefore apply 

rward, backward and sideways 

Maintenance Manual DG-808C 

Issued: June 2005 3.916. Check and grease the starter motor gear shaft (don't grease the starter motor 

gear) Check starter motor for tight mounting. There should be no excessive radial free play of the starter motor gear axle. With too much free play the starter must be exchanged. 

17. Clean the starter ring gear and check for damage. Check if the starter ring 

gear was bent forwards by the starter motor. There should be approx. 1mm (.04 in.) clearance between starter ring gear and drive belt. 

18. Remove the fairings which protect the drive belt. Check the drive belt for 

wear and tension (see sect. 1.11.5). If the drive belt shows signs of wear or if there are cracks/tears at the base of the belt teeth, the drive belt must be replaced. Check the 6 rollers which guide the drive belt for tight fit to their mounting brackets and for easy turning. If there is any significant friction in their bearings, the rollers have to be replaced. 

19. Clean the spindle drive, function check. Check the connection of the spindle 

drive to the engine especially for cracks in the fork. 

20. Option BBSA slipping-centrifugal clutch: Check the propeller stopper for 

wear and function, check especially the actuating spring. 

21. Check all the hinges on the engine compartment doors for proper fit and any 

cracks, tears etc. Check if hinge pins are secured properly. 

22. Oil all hinge points of the powerplant 

23. Check the time taken to extend the power plant. If it takes longer than 

described under sect.1.12.3 the gas strut has to be replaced. 

24. Check the engine retaining cable for wear and kinks. 

Check thimble and bolt of the upper cable connection for wear. Check the adjustment of the retaining cable according to sect. 1.12.4. If necessary adjust the cable at the adjustment screw in the rear end of the engine bay. 

25. Check the main bearings of the upper pulley for any free play. 
DG-808C 

3.10

move the lockwire, loosen the 

rque wrench, torque value see 

 

heck the terminals especially of 

s. 

 heat shrink tubing. 

ensure all equipment is secure and 

tioning of all systems and 

ngs assembled. 

3.7). 

hould not be more than 300 

mum. 

bes) EGT should be adjusted 

7, item 5. 

e test button for 10 seconds to 

must run with the same speed with 

et the time until the next 

u, see section 4.23. 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 3.113.5.2 Every 3 years 

Exchange the coolant, see sect. 4.16. 

3.5.3 After 50 resp. 100 engine hours 

Without optional BBSA friction/centrifugal clutch: The drive belt has to be exchanged after 50 engine hours. With optional BBSA friction/centrifugal clutch: The drive belt has to be exchanged after 100 engine hours 

3.5.4 After 400 engine hours 

After 400 engine hours the power plant must undergo a major overhaul. Apart from the items listed in section 3.5.1., the following items also need to be done: 1. Remove the power plant and remove the engine from the 

powerplant. Ship the engine to the manufacturer or an aircraft engine maintenance workshop approved by the manufacturer and by the authorities. 

2. Replace all the nuts and bolts on the engine 3. Replace the drive belt 

4. Replace the bearings of the upper drive belt pulley. 

3.5.5 After 6 years 

1. replace the gasket of the drainer valve 2. replace all coolant hoses and the coolant. 

3.5.6 When required 

1. If the fuel tank is excessively dirty or when the fuel gauge gives 

false indications, a thorough flushing of the fuel tank is required (see sect. 1.13.6). 

2. If the engine should run rough between idle and full throttle even 

after all the points in sect. 3.5.1. are OK, then it is possible that the membranes in the carburettors have hardened. They should then be replaced. 

3. After sudden power loss at full throttle: Check pistons and cylinders 

for seizing marks, see sect. 3.5.1 item 12. 

4. The fuel hoses have no life time restrictions but must be exchanged 

on condition. 
DG-808C 

4.1

ervicing work 

sic)

e root rib and attach an additional 

 to it. Also attach a line to the line 

which is near the wing root. 

allast bag out of its wing stand by 

e the valve and ballast tank 

Perlon line and loosen the hose 

 above procedures to install the 

 valve at the parting of the tank 

w tank. Clean and test the check 

 

ded pin points downwards, the pin 

both pins. For installation mount 

t.) long. The side without the 

led inboard. 

at the key ring will remain 5 cm 

t tensioned. By this method the 

the lines strain. 

s are still tensioned. If not, undo 

ove). 

ead, otherwise you won't be able 

ld be greased. Fill the new water 

d test the dump time. 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 4.24.2 Replacement of control circuit cables 

The following cable connections are approved: 3.2 mm dia. control cable construction 7x19 with Nicopress-sleeves 28-3-M Copper and tool No. 51-M850 or 63-V-XPM or 64-CGMP where the M groove is to be used. The above applies to the rudder cables and the tow release cable. The cable for the rudder pedal adjustment and the fin tank valve are 1.6 mm dia. control cable construction 7x7 with Nicopress-sleeves 28-1C Copper and the C groove for tool 64-CGMP should be used. The same type of cable is used for the control cables of throttle and manual propeller brake in Bowden outers with 2.6 mm inside diameter Attachment of the Nicopress sleeves should only be done using the respective tool. All the procedures and checks noted by the tool manufacturers should be followed. Please refer to aircraft inspection and repair FAA AC 43.13-1 B or later issues. Note: Control cables according to MIL-W-83420 I/A (was MIL-W-1511A) or ISO 2020 (was LN 9374) should be used. 4.3 Adjustment and servicing of the control circuit 

a) In all cases, new self locking nuts LN 9348 should be used. b) Bolts which are not secured with locking nuts have to be secured with Loctite 

243. Before installing the bolt clean the thread and the inside thread. Apply only 1 drop of Loctite on the bolt thread. Too much Loctite may cause damage when you try to loosen the bolt again. 

c) With all adjustment work, it should be ensured that the rod ends are not 

screwed out too far from the pushrod - see sketch below for allowable max. distances for the two sizes used. 

Note: All lock nuts (B) are secured by a spring washer (C) DIN 6798 I. Be careful not to loose that washer! 

A max. of x  mm inch M 6 36 1.4 M 8 60 2.36 x 

A 

C B 
DG-808C 

4.3

arriage (main wheel) 

ding gear box to compensate the 

y retract by itself when unlocked 

e glider is not in the normal 

make sure that inadvertent 

control system: Use a screw 

hat the bolts can be removed. 

ever by loosening the attachment 

ing pin comes free out of the left 

x remove the three bolts 

W42. After removing the 

shrod 8FW47 from bellcrank 

crank 8FW42. 

partment floors, the axle can be 

ough a 20 mm (.79 in.) dia. hole 

e side. 

ble should be provided - see sect. 

Maintenance Manual DG-808C 

Issued: June 2005 4.44.4.4 Filling and bleeding the hydraulic disc brake 

(Option) 

Note: filling and bleeding the system has to be done from the lowest point which is the brake cylinder assembly at the wheel. Otherwise the system can’t be bled completely. Necessary tools:1. 1 open-end wrench 1/4" = 6.35 mm for the bleeder valve at the cylinder 

assy.. 

2. 1 open-end wrench 11/16" = 18 mm. 

3. 1 Plastic syringe acid resistant, volume ca. 100 ml (6 cu.in.). Use this 

syringe for brake fluid only! 

4. 1 bleeder assy. Tost No. 075890. 

5. 1 m (3 ft.) transparent PVC hose inside diameter 3 mm (0.12 in.), fixed to 

syringe and bleeder assy. with hose clamps. 

6. Instead of items 3 –5 we recommend to use the Tost No. 059010 filler assy. 

For hydraulic disc breaks including 075890 bleeder. 

7. Brake-fluid DOT 3, DOT 4 or SAEJ 1703. 

1. Preparations- raise the fuselage, extend the landing gear - fix left wheel door in the fully open position - set the airbrake control in the retracted position - remove the baggage compartment floor and rear cover. Remove the reservoir 

mounting plate. Check that the actuating cable for the master cylinder is loose and if the piston rod of the master cylinder is at its stop. 

- Remove the mounting bolts of the main brake cylinder. Lift the cylinder so 

far that the cylinder comes to a higher position than the highest point of the brake hose. Hold the cylinder in this position for filling. 

2. Filling- remove the cover of the reservoir including the gasket. - fill the syringe with brake fluid, therefore screw off the black part of the 

bleeder assy., eliminate all air bubbles, reassemble the black part. 

- remove the protection cap from the bleeder valve, attach the bleeder assy. 

and fix it with the wrench 11/16". 

- open the bleeder valve at the cylinder assy., use the 1/4" wrench, fill in 

slowly the complete volume avoiding air bubbles. 

- fill the complete system up to 15 mm (0.6 in.) above the lower edge of the 

reservoir. 
DG-808C 

4.5

otate the cylinder so far, that the 

he front end. Continue filling the 

n.) below the upper edge of the 

assy., then close the reservoir 

sy.. 

cap. 

heir correct positions. 

lled brake fluid. Clean all parts 

l, don't use fuel or solvents. 

 pressure when the wheel brake 

engage at the same point every 

 system again 

ks:

ld it in this position for 2 

ually for leaks. If necessary 

alings and bleed the system again. 

e between the master cylinder and 

rake extension height. The 

e glider rigged. 

using the syringe. 

struction. 

Maintenance Manual DG-808C 

Issued: June 2005 4.64.5 Fixing excessive free play of the canopy 

Shrinking of the fibre reinforced plastic material may result in free play between the canopy hinge 8R48 and the canopy. 

You can fix the free play as follows: 

a) Take off the canopy and remove the emergency release spring. b) Tape the hinge completely and coat it with demoulding agent. c) Roughen the depression for the hinge at the canopy carefully with 

abrasive paper. 

d) Fix a piece of wood 10 by 10 mm (3/8 in.), 2 mm (1/12 in.) thick with 

double-sided tape at the rear end of the hinge (see sketch). Put on the canopy and try to lock the canopy to the hinge. If this is not possible remove a small amount of the wood thickness. If there is still free play, use a thicker piece of wood.

e) Mix epoxy resin with cottonflocks and apply it in the depression see c). f) Reinstall, close and lock the canopy. g) After the resin has cured, take off the canopy again. h) Trim the depression, remove the tape and reinstall the canopy. i) Finally check the canopy emergency release according to flight manual 

sect. 7.12. The opening force for the emergency release should in no case exceed 20 daN (44 lbs.)! 

wood 

8R48 
DG-808C 

4.7

ns 

gs or to remove the flaperons 

 the tip parts (approx. 20 mm 

e and the screw (Allen key tool 

rear. 

 wingtip for removal. 

control surface horns at the 

n key wrench 4 mm, 0.16 in.) 

at the inboard flaperon hinge 

e flaperon from the wing by 

3. 

ng nuts (M5 DIN 985-8 zn). 

cure the bolts with a drop of 

e horns with polyester resin. 

fairings interfering. 

with screw and white tape (e.g. 

.3. 

Maintenance Manual DG-808C 

Issued: September 2007 TN800/34 4.8

4.7 Control surface seals and turbulators 

Note: To minimise the friction of the seals, the trailing edge of the seals should be chamfered. Apply a fine grinding paper (e.g. 400 grit) between sealing and control surface and move it up and down in spanwise direction to sand the trailing edge of the sealing. Warning: Use only original materials see section 8. Otherwise the function of the sealings is not guaranteed. Sealings which are too loose may cause control surface flutter. 4.7.1 Wing upper surface The sealing is installed in a groove at the trailing edge of the wing. Curved Mylar seal is glued into the groove with film tape at the leading edge of the sealing. PVC tape is glued over the sealing to cover the gap between wing and sealing. The leading edge of the PVC tape shall be 5 mm (1/5 in.) in front of this gap. 4.7.2 Wing lower surface turbulators a) Version with combi tape: Sealing and turbulator are combined (combi sealing). The combi sealing is already equipped with selfadhesive film tape. Prior to removing the old combi sealing mark the position of the turbulator leading edge with a pencil on the wing surface, otherwise see sketch distances a. The inboard combi sealing is 7.0 m (22.97 ft.) long and 43 mm (1.7 in.) wide. The outboard part is 1.45 m (4.76 ft.) long and 38 mm (1.5 in.) wide. b) Version with dimple tape: Instead of combi tape a dimple tape may be installed as turbulator. The sealing of the flaperon gap is done with the internal sealing according to sect. 4.9.1. Operation without this sealing is not permitted. The leading edge of the tape is located at distances b in front of the flaperon trailing edge. 

y measured from fuselage centre line 1 in.=25.4 mm

 . . . . . 

hinge linetrailing edge

a 

Position y 

mm 

a 

mm 

b 

mm 

flaperon root 380 155 158 contour brake 4500 130 133 parting 7250 95 98 flaperon tip 8650 78 81 

b 
DG-808C 

4.9

m (1.7 in.) wide selfadhesive 

r side of the flaperon see sketch. 

 the position of the front end. Cut 

the wing.. 

sealing is prohibited. 

ith 38 mm Teflon-glass-fabric 

he internal sealing first. Peel off 

emains of the glue remain on the 

careful not to bend the combi 

manently and that it doesn’t come 

 on the control surface horn. 

he flaperon to its max. negative 

um powder onto the flaperon 

ax. positive displacement and 

eron surface.. Clean the gluing 

cement again and fix in this 

ving its cover into the slot 

 up to the glue film of the combi 

s fabric tape to the wing with 

cut off here full 

displacement 

Teflon tape 

Maintenance Manual DG-808C 

Issued: June 2005 4.10Press the Teflon-glass fabric tape with a wooden stick into the gap between aileron and wing and press the fabric tape to the aileron surface. Then deflect the aileron several times in both directions. If there is still a noise which sounds like the fabric sticking to the aileron and getting loose again, you should blow compressed air into the fairings of the control linkage pushrod to distribute the talcum powder. Glue a PVC tape (19mm wide) over the leading edge of the sealing. Screw on the control surface horn, securing the bolts with Loctite 243. Glue the fairing again to the control surface horn with polyester resin. Apply pressure when gluing to prevent the fairings interfering. 

Sealings shown for version with dimple tape 
DG-808C 

4.11

r and lower surface. 

osition of the turbulator leading 

otherwise 

om fuselage centre line 1 in.=25.4 mm 

ylar seals with scarfed leading 

rips. 

on Y 

mm 

a=b 

mm 

c 

mm 

 0 

72 

275 

267,5

137,5

134 

ator tip 1160 155 77,5 

PVC tape 

0 mm

film tape 

21 mm 

fin trailing edge

5 mm 

Maintenance Manual DG-808C 

Issued: June 2005 4.124.8 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. You must produce holders according to drawing 8V 96 (enclosed in this manual). One with 6.5 mm (1/4 in.) diameter hole and 4 (or 5 for flaperons without parting) with 5.5 mm (0.22 in.) diameter hole. Fit the holders to the flaperon hinge pins. Part 1 (6.5 mm dia) to hinge 1 (at root). Other parts to hinges 4, 7, 10, 13 and 17 in case of flaperon without parting. 

Clamp the holders to the working bench with screw clamps. Remove the flaperon and adjust all hinge points to be in line. A max. tolerance of + 0.5 mm 

(0.02 in.) in up and down and fore and aft direction is allowed. Fix the holders to the bench when in line. Install the flaperon again and measure the load at the trailing edge at the root 122 mm (4.8 in.) behind hinge axis, see sketch.

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. Execute this measurement min. 3 times to be sure that no measuring error occurs. The difference between up and down value should be no more than 80 g (0.036 lbs.). Otherwise the friction is too high and must be reduced first to obtain a reliable measurement. 

part 2 part 2 part 2 part 1 

122 

loop of tape Spring scale should have a max. 

reading of 1 kg (10 N) or 2 lbs. 1 graduation should be 20 g (0.2 

8V96 N) or 0.04 lbs. 

spring scale 

10 7 4 1 
DG-808C 

4.13

ubing 

m heat-shrink tubing is used. For 

often has to be removed. For 

p a new piece of heat-shrink 

he tubing until it shrinks and 

 mounting bolts (lockwire) which 

cured with Loctite 243 (Loctite 

section with a hot air gun to 

ad of the bolt and the inside 

ocedure use Loctite 18896. 

 apply the Loctite bolt and inside 

 Loctite 7063. 

ith compressed air. Repeat two 

read. Too much Loctite may 

again. 

o the thread in the hole and not to 

d with red securing paint which 

rticular point. 

tallation of the bolt. 

of production date. The 

bottle. 96A means January 1996, 

Maintenance Manual DG-808C 

Issued: June 2005 4.144.11 Replacement of wing fuel tanks (Option) 

Disconnect the plastic fuel line inside the wing at the quick connector attached to the wing root rib. Loosen the red black marked perlon cords at their attachment at the root rib. Attach an extension line 3 mm diameter (1/8 in.) 5 m long to the red perlon line. Remove the fuel tank by pulling on the perlon cord marked red and black on the fuel line. Disconnect the wire for the electrostatic connection. Installation: Follow the removal procedure in reverse. Fill the tank and check for leaks. Tanks type Uniroyal part NO. 4F28: Note: The tanks have no ventilation lines 
DG-808C 

4.15

elt 

in MM) 

ve belt is accomplished by 

which carries the upper drive belt 

(carbonfibre tower). 

from fork 8M119. 

otherwise the retraction bungee 

side the rear end of the fuselage. 

115 by marking the position of 

 

a position that there is no risk 

 the proximity switch when 

h fix the flange of axis 8M115 to 

exagonal head, 1 x countersunk 

m open end spanner at the fork 

e in the flange of axis 8M115 

in upward direction at its front 

n increases the belt tension (view 

nto place is not quite tensioned, 

up to the next but one mounting 

e the drive belt tension according 

 upper and lower drive belt 

rive belt covers) from the 

rive from the propeller mount. 

 sect. 4.13. 

Maintenance Manual DG-808C 

Issued: June 2005 4.16

5. When reassembling mount the axis 8M115 2 mounting holes prior 

to the marked position. Fix the axis with min. 2 mounting bolts. 

6. Check and if necessary correct the drive belt tensioning see b). 

d) Initial setting of eccentric axis 8M115

If the marking was lost or if a new axis is to be installed, the eccentric must be positioned as follows: Remove the sealing cap 8M118/1. The groove in the front end of the axis shall point downwards. This is the lowest position of the eccentric. From this position rotate the axis in a clockwise direction (see a) 5.) from 1 mounting hole to the next and fix the axis min. 2 bolts in each position to check the drive belt tensioning. Proceed until the correct tensioning is reached. During this the axis should not be rotated more than 180° (groove in upper position). However it should be impossible to reach this position. 

e) Reassembly

1. Reassembly is the reverse of disassembly. Use Loctite 243 to secure 

all screws and bolts except for the propeller mounting bolts. Caution: When reassembling the drive belt covers be careful to use the correct screws. Screws which are too long will damage the belt! 

2. If the position of the axis has been changed the fork 8M119 must be 

brought to vertical position again. Screw out the fork (axis already assembled with all 6 bolts). Loosen the distance washer 23 x 32 x 1 from the axis 8M115. Apply a suitable 2 component metal adhesive (e.g. UHU Plus 300) between 8M115 and the washer. Screw in the fork 8M119 again using Loctite 243 for securing until the fork is in vertical position. The glue should be pressed together to less than 1 mm thickness. Let the glue cure before operating the engine. 

3. Adjust and secure the proximity switch according to sect. 1.14.15. 

f) Changing the relation of propeller to engine see sect. 1.11.4 

1. Execute work according to a), b) and c) items 1,2 and 3. 2. Mark upper drive belt pulley and drive belt with a felt pen or with 

tape. 

3. Move drive belt forward as far as possible on both pulleys. Then lift 

the belt off the upper pulley and rotate the pulley against the drive belt. 
DG-808C 

4.17

and tolerances

sed in MM) 

drive belt cover. 

m the right hand side (inside) 

f the drive belt cover (counted 

 cord around the left hand side of 

 other side of W57. 

ring balance into the cord. 

rive belt surface and the outer 

me station from the left hand side 

e probe of a vernier caliper. First 

hen with 100N (10kg, 22lbs.). 

m (0.236 in.) and should not 

ference is smaller than 6 mm the 

he crankshaft is excessive. If the 

y slip and the relation propeller to 

l clutch: The drive belt tension 

check the belt tension again after 

essary. 

Maintenance Manual DG-808C 

Issued: June 2005 4.184.13 Replacing the bearings of the upper drive belt pulley 

see drawing 8M110 (enclosed to this manual) 

a) Removing the bearings

1. Remove the propeller. 2. Remove the proximity switch. Its best to remove the switch together 

with its mounting plate 8M138. Mark the position prior to removal. 

3. Remove the drive belt see sect. 4.11. 4. Remove the sealing cap 8M118/1. 5. Bend up the securing washer 20 DIN 462. 6. Screw off the nuts KM4 one after the other. 

Note: left hand thread.Use one of the 2 specially bent hook spanners according to drawing W51 (encl. with this manual). Remove the antirotation securing washer. 

7. Now you can pull off the complete pulley 8M111 from the shaft 

8M115. 

8 Take the inner ring and the rollers of the front bearing out of the pulley. 9. To remove the outer rings of both bearings from the pulley you have to 

produce 2 pieces of round material each 100 mm (4 in.) long and with 47 mm (1.85 in.) and with 53 mm (2.09 in.) diameter. 

10. Press out the outer rings together with the Nilos rings carefully using a 

press or a hammer. 

11. Pull off the inner ring of the rear bearing together with part 8M117/1 

from shaft 8M115. Use a suitable puller assy.. 

b)Installation of the new bearings 

1. To press the outer rings of both bearings into the pulley you have to 

produce 2 pieces of round material each 30 mm (1.6 in.) long and with 51 mm (2 in.) and with 57 mm (2.24 in.) diameter. 

2. Press in new outer ring together with new Nilos rings. 3. To press the inner ring of the rear bearing to the shaft you have to 

produce a piece of tube with 32 mm (1.26 in.) inside diameter and 90 mm (3.54 in.) long. 

4. Press the inner ring together with part 8M117/1 to the shaft. 5. Fill the space for both bearings with grease. 6. Apply grease to the inner ring of the bearing and place the rollers onto 

the ring. Apply enough grease to completely fill the bearing. 
DG-808C 

4.19

re. It ́s best if the powerplant 

irection. 

e front bearing into place. Put 

e first one of the KM4 nuts. 

anner see a) 6. until the pulley 

a loose nut. Put on a 

rew on the second nut. Secure 

 nut with a hook spanner so that 

hten the second nut as far as 

he pulley. No free play is 

into the grooves of the rear nut. 

t it into place. 

rding to sect. 4.11. 

eck its adjustment, see also sect. 

h lockwire according to sect. 4.18. 

 

V 

V 

62 

MT3 

e

Maintenance Manual DG-808C 

Issued: June 2005 4.20

4.14 Removal and installation of the tension gas-strut 

(engine extension mechanism) 

a) Removal: 

1. Take a piece of tube with 12mm (.47 in.) inside diameter and 80 mm 

(3.15 in.) length and cut it to receive two halfshells. 

2. Retract the powerplant until the gas-strut is extended a little further than 

80mm. 

3. Place both halfshells onto the piston rod of the gas-strut. Extend the 

engine a little further, so that the two halfshells block the gas-strut. 

4. Remove the gas-strut. 

b) Installation is the reverse of removal 

c) Installation of a new gas-strut 

1. Extend the new gas-strut with a pulley block to place the halfshells or 2. Install the gas-strut to the front mounting point in the aircraft and 

produce a metal plate with two holes diameter 8 mm (.32 in.) 80 mm (3.15 in.) apart. Bolt this plate to gas-strut and propellermount and retract the engine to extend the gas-strut far enough to place the halfshells. Remove the plate. 

d) Securing the rod end to the piston rod

The rod end of the gas-strut must be glued onto the thread of the piston rod with Loctite 638. The correct securing is marked by a red dot of marking paint on piston rod and rod end. After removal of the gas-strut check if the marking is existing and not damaged. If not the rod end must be screwed off and glued on again. The same applies with installation of a new gas-strut. Remove any remains of Loctite and any dirt according to the instructions in section 4.8. To tighten the screwed connection, hold the piston rod against rotation using a small pipe wrench, wrap a piece of fine emery cloth around the end of the piston rod to protect the rod. In addition the rod end is secured with a roll pin 2.5x14 DIN 7346 St, see sketch.
DG-808C 

4.21

ble 

 to diagram 14a 

gine bay floor. 

he propeller mount. Let the cable 

ngee may jump from its pulley 

 The bungee pulley is accessible 

x. 

the rear engine bay floor until 

ble. 

om disappearing into the fuselage 

Don’t damage the bungee! Don’t 

Nicopress sleeves to the bungee. 

cable must be inside the second 

on the cable and wrap Tesaband 

eeves. 

t screw through the rear engine 

justment screw. Check if the 

n place and fixed and if the 

e adjustment screw, see diagram 

uselage 

imble and Nicopress sleeve to the 

Adjust the 

ction 1.12.4. Tighten the cable 

e excess cable. 

ble. See section 1.12.4. 

crew at the rear bulkhead. 

ne bay floor. 

3 m (91 in.) long, type see section 

Maintenance Manual DG-808C 

Issued: June 2005 4.224.16 Filling and bleeding the cooling system 

Please refer to diagram 9 Coolant: 1 part glycol and 1 part distilled water (up to appr. -40°C, -40°F), you will need appr. 1.8 liter , 0.475 US.gal.. 

4.16.1 Inspection of the coolant pump 

1. Extend the engine 

2. Remove the coolant hose from the radiator (upper end). Insert the test 

adapter W59 (drawing see enclosure to this MM) into the hose and secure with a hose clamp. Install a PVC hose (instrument line) on the other end of the adapter and put its end in a calibrated container. 

3. Switch on the ignition and measure the time needed to fill 0.2 liters into 

the container, then switch off the ignition immediately. Otherwise the pump will suck in air and bleeding may be difficult. Normal time is between 15 and 20 seconds. 

4. If the time needed exceeds 25 seconds the pump is worn and should be 

exchanged. Repeat the test after installation of the new pump. 

5. Remove the adapter and connect the coolant hose to the radiator again. 

6. Remove the screw cap of the radiator. Press down on cap for easier 

handling.and fill in the coolant from the test, if necessary refill coolant. 

7. Switch on the ignition to run the coolant pump. Run for approx. 1 

minute. Switch off the ignition. If necessary top up the radiator. 

8. Close the radiator cap. 

4.16.2 Removal of the coolant 

a) Prior to removal of the coolant check the coolant pump see above, b) Retract the engine until the engine doors just stay open. c) Remove the straight hose connector GS 16 from the coolant hose on top 

of the coolant pump and replace it by a T-connector TS 16 (supplied with the glider service set). 

d) Install a hose with 16 mm (0.6 in.) inside diameter to the T-connector. 

Hold the hose into a container placed below the lowest point of the cooling system. 

e) Extend the engine. After all liquid has run out of the system, switch on 

the ignition to run the coolant pump for a short time. 

f) Replace the T-connector by the straight connector again. 
DG-808C 

4.23

owerplant. 

 Press down on cap for easier 

ator is completely filled. 

nt pump. Look into the radiator, 

this is not the case there may be 

p in the upper coolant hose. 

e coolant starts bubbling. Run the 

witch off the ignition. If necessary 

pprox. 1⁄2 minute at full throttle. 

ve the radiator cap and check the 

d be approx. 2 cm (0.8 in.) below 

p up to this level. 

Maintenance Manual DG-808C 

Issued: June 2005 4.244.17 Installation and removal of the powerplant 

see diagram 8 

4.17.1 Removal of the powerplant General notes: − Remove all Ty-raps (cable fasteners) which may hinder engine removal. − If necessary heat carefully all bolts secured with Loctite with a hot-air gun to 

enable easy removal. 

− Study the notes for engine conservation (see engine manual) prior to 

removal of the engine. 

− To lift out the powerplant from the engine compartment you need a strong 

helper or a crane. 

Necessary toolsSocket wrenches: 6, 8, 10, 13, 14, 17, 19 mm Open end spanners: 8, 10, 13, 14, 17, 19 mm Allen key wrench: 6 mm 1 wire cutter 1 hot-air gun 1 small screwdriver 1 roll insulating tape 1 sharp knife 2 pliers 
DG-808C 

4.25

ller fixing screws and remove the 

ch. Then pull off the propeller. 

section 4.17. 

ffler when the engine is 

nner. 

ng the hose clamp from the 

rench. Then loosen the hose 

h a 6 mm socket wrench. Pull off 

plug the line with a 6mm bolt. 

arburettor. 

wden wires for the propeller 

e rear side using a small 

panner. 

electric wiring of the starter at the 

ating cap from the positive 

ring from the starter motor with a 

ed marking). Insulate the wire 

e earth wire (wire with blue 

cable from the propeller mount 

mm open end spanner. Let the 

he fuselage, otherwise the 

 from the pulley in the fuselage. 

tions of the waterpump. Remove 

opening the two hose clamps 

ket wrench (To open the upper 

ine a little). Pull the pump out of 

on. If necessary remove further 

Maintenance Manual DG-808C 

Issued: June 2005 4.26

II) Retract powerplant almost completely 10. Disconnect the electrical connections at the firewall: 

a) Disconnect the multiple plug of the wiring set (from serial no. 8-

103 on installed in the firewall behind a cover plate). 

b) Only with EGT-option: Screw off the two screw-in-plugs for the 

EGT probes . 

c) Now arrange all wires in a way to enable easy removal of the 

powerplant from the engine bay. For this purpose it might be necessary to remove some further Ty-raps. 

11. Separation of the extension/retraction unit from the propeller mount: 

a) Spindle drive: Retract powerplant until the propeller mount is 

approx. in horizontal position. Unscrew the bolt which fixes the fork to the spindle drive. Then lift the powerplant a little by hand to pull out the bolt and let down the powerplant into the engine bay. 

b) Disconnection of gas-strut from the powerplant s. section 4.13. 

12. Bend up the securing washers at the two bolts at the hinge axis of the 

propeller mount. Unscrew the bolts with a 19mm socket wrench, lift the powerplant to minimize the load on the bolts and remove them including the brass bushes. Finally lift the powerplant out of the fuselage with two persons. 
DG-808C 

4.27

peller mount 

 mount screw four long bolts M 

d of the engine block. This 

the powerplant can be placed on 

manual) with 

 propeller mount by unscrewing 

ch. 

on 4.11a) and c). 

ding starter ring gear from the 

 pulley. 

h the hot-air gun, then remove it 

e crankshaft thread. 

M5x20 DIN 912-10.9 to the drive 

 DIN 933-8.8 into the puller and 

ecure the puller with a 30 mm 

pulley resists coming off you 

with a hammer to loosen the 

Maintenance Manual DG-808C 

Issued: June 2005 4.284. Disconnect the electric wiring coming from the magneto housing near the 

propeller brake. First remove the heat shrink tubing carefully with a sharp knife. 

5. Remove the mounting bolts and detach the starter motor. 6. Disassemble the fuel lines from the primer to the carburettor at the 

carburettor using a small screwdriver to open the hose clamp. Plug the line with a 6mm bolt. 

7. Remove the EGT probes from the exhaust manifold with a 7 mm socket 

wrench (Option). 

8. Unplug the electrical wiring of the coolant temperature probe on the 

cylinder head near the probe. 

9. Empty the coolant system: Remove the coolant see section 4.15.2. Use a 

bucket to catch the coolant (approx. 2 litres). 

10. Remove the spark plug connectors from all spark plugs. 11. Remove coolant outlet (on top of the engine) from the cylinder heads 

using a 4mm Allen key wrench. Seal openings at the cylinder heads with tape. Remove the hose of the coolant inlet (near the starter ring gear) and seal the inlet with tape. 

12. Remove the four fixing screws of the cylinder heads to the CRFP plate 

with a 6mm Allen key wrench. Fasten together the group of ground wires which are fixed by the front right screw with a wire or similar. If necessary remove the front right hand side cap nut (cylinder head bolt). 

13. Heat the engine’s final four fixing screws at the front side of the crankcase 

with the hot-air gun and unscrew them with a 5mm Allen key wrench. 

14. Now rotate the propeller mount a little forward and pull it from the 

crankshaft. 
DG-808C 

4.29

w the propeller brake fixing plate 

three screws with a 6 mm Allen 

ld with tape and seal the airfilter 

ute for shipping the engine for 

n 21 mm (13/16’’) socket 

e. 

 can be removed by unscrewing 

a 6mm Allen key wrench. Seal 

e filter from the carburettor 

a small screwdriver. Seal the 

m Allen key wrench. Seal outlets 

Maintenance Manual DG-808C 

Issued: June 2005 4.304.17.3 Reinstallation of the powerplant Reverse the procedures for removal mentioned above. Note sections 4.11, 4.13, 4.15 and 4.21! Use only new selflocking nuts for reinstallation. Use Loctite 243 to secure all threads and screws without selflocking nuts. Use new gaskets for the coolant outlet.Reinstallation of the starter ring gear 1. When reinstalling the starter ring gear adjust the propeller position versus 

the engine compression point according to sect. 1.11.4 via the drive belt. 

2. Install the screw at the crankshaft without using Loctite and tighten with a 

torque of 100Nm (73 ft lb). Hold the Propeller to counteract the moment. 

3. Tighten the drive belt according to sect. 4.12e). 4. Reinstall the proximity switch and check its adjustment according to sect. 

1.14.15 and correct if necessary. 

5. Reconnect the spindle drive. 6. Rig the wings to the fuselage and secure the glider. Start the engine, apply 

full throttle for a short while (max. 30 seconds) and stop the engine again. 

7. Retorque the screw at the crankshaft with 100Nm, to accomplish this the 

spindle drive must be disconnected again. 

8. Start the engine, apply full throttle for a short while (max. 30 seconds) and 

stop the engine again, retorque again. Repeat this procedure until the screw can’t be turned any more with the same torque. Normally it is necessary to repeat the procedure 4 times. After the last retorque remove the screw, apply Loctite 243 and torque again with 100 Nm. 

9. Install a new selflocking nut M10DIN985-8zn to the spindle drive bolt. 10. Check if the propeller position versus the engine compression point is still 

in the limits. If necessary correct according to sect. 4.12 f). 
DG-808C 

4.31

ors 

moval and assembly of the 

orking at the carburettor: 

 nut at the mounting point of the 

engine bay wall. Unhook the 

 pins. Remove the hinge pins. 

ne doors close. Move the left 

you can lift the rear rubber cord 

r and lay it down on the right 

e springs and hinge pins of both 

avel and lift both doors away. 

e new selflocking nuts. 

Maintenance Manual DG-808C 

Issued: June 2005 4.324.19 Securing the propeller bolts 

1. Use lockwire with min. 0.8 mm (0.03 in.) diameter. 2. Secure the propeller bolts as follows: 

a) Slide the wire through the hole in the bolthead and bend it around the head. 

The wire should run tangential to the bolthead so that it secures the bolt clockwise to tighten it. Direct the end of the wire which was laid around the head underneath the wire which runs through the hole. 

b) Twist both ends of the wire clockwise up to the other bolthead. Slide the 

upper wire through the hole in the bolthead and bend the other wire around the head. Twist with max. 8 rotations per inch. 

c) Direct the end of the wire which was laid around the head underneath the 

wire which runs through the hole. Twist the ends anticlockwise up to the third bolt. 

d) The end should be twisted min. 3 max. 8 rotation in clockwise sense. Cut 

off the surplus and bend the end to prevent injuries. 

Caution:Don't damage the lock wire. Also minor scratches or removal of the galvanisation have to be considered as damage. 
DG-808C 

4.33

150 part no. 43171402 

 part no. 432372500

cuits. It is equipped with a 

h magneto generator for 

raft. The ignition unit is adjusted 

o servicing. In case of trouble 

s without running out of fuel. 

defective. 

m, there are no sparks at the spark 

harged enough to reach this rpm 

d battery is approx. 600 rpm). 

 with ground or with each other 

ion. For checking gain access to 

ctronic boxes by removing Ty

resistances between wire 301 

wire 302 and ground (plugs 

on on) and zero (ignition off). 

off the rpm goes down 

king gain access to the connector 

emoving Ty-raps and heatshrink 

on boxes from one box to the 

wires see drawing 8E210 

nction now changes to the other 

Detect the faulty one by mutual 

a plug from a box. 

Maintenance Manual DG-808C 

Issued: June 2005 4.34

b) If the malfunction remains on the same circuit, then carry on according 

to the following instructions: 

b)1 Check the shorting cables see above. b)2 Checking the ignition, trigger and charging coils 

Disconnect the connector plugs from the electronic boxes see 1. and measure the resistance: item pin nos. resistance (Ohm) primary ignition coil 1 76 and 77 (right) appr. 300 primary ignition coil 2 79 and 80 (left) appr. 300 trigger coil 1 75 and ground (right) appr. 170 trigger coil 2 78 and ground (left) appr. 170With other values identify the defective part by the wire numbering see wiring plan 8E204. 

b)3 Checking the air gap between trigger coils and actuators (metal plates 

on the magneto housing) with a gauge. The gap must be 0.45 – 0.55 mm (0.018in. –0.022in.) wide 

c) Checking the generator coil: Disconnect the engine main plug and 

measure the resistance between wires 491 and 501. It should be appr. 0.5 Ohm. 

Warning: Starting and operating the engine with spark plug connectors taken off can damage the ignition electronic boxes. Check for spark only with spark plugs fitted to the connectors and spark plug bodies having ground connection. 

4) Generator

a) If the red generator control light shines although the engine is running: - Check the generator. 

Disconnect the right hand side plug (in direction of flight) from the control unit. Measure the resistance between pins A1 and A2 with the engine stopped. It should be 0 up to 1 Ohm. Measure the resistance between pins A1 and ground and A2 and ground. It should be infinite. 

- If the measured results differ from the nominal values, the generator is 

defective and must be replaced. 
DG-808C 

4.35

nd check all pins visually and by 

ntrol unit must be replaced. 

tteries: 

 If no defect can be discovered 

the solar panel and regulator. 

s not adjustable. 

Maintenance Manual DG-808C 

Issued: June 2005 4.364.21 Installation and removal of the extension/retraction unit 

When installing the extension/retraction spindle drive proceed as follows: 

First, don’t tighten the bolt which connects the spindle drive to its front mounting block. Extend the powerplant to the position (see sketch). Then tighten the bolt. The reason for this procedure is to make shure that the rubber bush in the mounting block will be twisted approx. by the same amount in upward and downward direction. False adjustment may result in cracks in the rubber. 

900mm 
DG-808C 

4.37

EI-NT 

r of the DEI-NT) 

-in electrical fuel pump. 

he lower side of the mechanical 

ate can. 

he tank is drained. 

curacy it is necessary to keep the 

ions. 

 wheel and tailwheel on a flat 

I-NT by pushing the selector knob 

eps twice for 2 times. 

ght log, Set up 

e turning knob: 

bration of the fuel gauge with 

 will be displayed, rotate the 

sh the selector knob to execute 

 next menu point: 

ation of the fuel gauge with full 

e displayed, rotate the selector 

lector knob to execute the 

NT beeps twice for 2 times to 

pushing the selector knob (right 

imes. 

Set up 

n the propeller into retraction 

otor power to turn the propeller 

ed off) – standard value 35%, 

Maintenance Manual DG-808C 

Issued: June 2005 4.38Calibration of the primer PRIMER DOSE: % of the max. amount of fuel injected by the primer, max. 99% - standard value 99%. (With 0°CHT. the adjusted amount of fuel will be injected. The amount of fuel will be reduced linearly to 0 at 40° CHT). PRIMER DURATION: Post starting injection of the primer, max. 99% of the time programmed in the control unit (40 seconds), standard value 99% Activation or deactivation of the electrical propeller brake (Option) PROP BRAKE: Activation of the electrical propeller brake (Option), Push the selector knob, N will be displayed, rotate the selector knob, Y will be displayed, the propeller brake is activated. Rotate the selector knob N will be displayed, the propeller brake is deactivated. Push the selector knob to save this adjustment. Notes: If no electrical propeller brake is installed this function must be deactivated, otherwise failure messages will be displayed. Activation or deactivation of the low temperature warning FREEZE WARNING: Activation or deactivation of the warning message. Adjustment similar to Prop Brake. You may deactivate this warning in case no watertanks are installed. When deactivated the OAT screen will still blink at low temperatures. Activation or deactivation of the acoustic warning signals JOINT WARNING OUTP: Activation or deactivation of the signals to draw the pilots attention to the messages. Adjustment similar to Prop Brake. Note: The signal for the stall warning will not be deactivated. Download of flight log and service data FLIGHTLOG → PC: Push the selector knob, N (no) will be displayed, rotate the selector knob Y (yes) will be displayed, push the selector knob to reset start the download of the recorded data. The PC must be connected to the serial interface (socket close to the radio). Download instruction can be found in the amendment to this maintenance manual. Resetting the time until the next 25 hour maintenance RESET MAINT. TIMER: Push the selector knob, N (no) will be displayed, rotate the selector knob Y (yes) will be displayed, push the selector knob to reset the time to the service-interval (25 hours). Push the selector knob until the DEI-NT beeps twice for 2 times to return to the flight screen. 
DG-808C 

5.1

own. 

ks. 

ble scales are available under the 

p of the aft fuselage boom has a 

he wings are level and hold so that 

es are available, otherwise see 

rs through points a and b. (See 

erent masses due to deflection of 

 weighing and adding W1 and 

ll components. 

ed above, calculate the C.G. as 

excludes pilots and parachutes. 

ballast from the cockpit. 

lus pilot, parachute, trim ballast 

ra, cushions, etc.). In addition, 

e adjusted as in flight. 

Maintenance Manual DG-808C 

Issued: June 2005 5.2

Datum (BE): Wing leading edge at root rib Levelling line: Aft fuselage boom slope 1000:37 (tail down) Moment arms of pilots and equipment see flight manual sect. 6.9 Empty weight C.G. measurements After the addition or deletion of equipment or accessories, repairs, painting, or any change in the aircraft that could influence the weight and balance; a new weight and balance must be carried out. Aircraft certified as Standard Category must have the weight and balance carried out by a licensed Airframe Mechanic. Empty weight C.G. range is determined by reference to the diagram in sect. 6.8.8 of the flight manual. If the C.G. is out of limits, adjustments may be made by ballasting or by relocating equipment or accessories. The result has to be entered in the flight manual section 6.8.7 and in the aircraft logs. If the min. cockpit load or the max. flight mass without waterballast have changed, the new values are to be entered in the cockpit placard. Weight and balance must be carried out at least every four years. C.G. shift due to extension of the enginesee flight manual section 6.9 

b 

x 

W2 

pattern 1000:37 

W 

BE 
DG-808C 

6.1

Certification No.

) TS 10.210/15 

. 6421369 

. 6423369 

) TS 10.210/19 

. 7421369 

. 7423369 

peed ranges marked as indicated 

Certification No.

m) TS 10.220/46 

t.No.4110 

.No.4330 

m) TS 10.220/47 

.No.4220 

m) TS 10.220/48 

.No.4550 

d altimeter with fine range 

Certification No.

40.070/32 

40.071/05 

 bars 

40.073/11 

Maintenance Manual DG-808C 

Issued: June 2005 6.2Compass 

Manufacturer Type Certification No.

PZL B - 13 FD 19/77 Ludolph FK 16 10.410/3 Airpath C 2300 Hamilton H I 400 TSO C 7c Type1  46 MFK 1 (only as additional 

equipment.) 

The compass should be compensated in the A/C. A deviation table must be installed if deviation is more than 5°. VHF transceiver 

Manufacturer Type Certification No.

Dittel FSG-40 S 10.911/45  FSG-50 10.911/71  FSG-60 M 10.911/72  FSG-70,71 M 10.911/81  FSG-90 0.911/98JTSO  FSG 2T LBA.0.10.911/103JTSO Becker AR 3201-(1) 10.911/76  AR 2008/25 (A) 10.911/48  AR 4201 JTSO-2C37 D, ED-23A Filser ATR 720 A 10.911/74  ATR 720 C 10.911/83  ATR 600 O.10.911/106JTSO  ATR 500 LBA.0.10.911/113JTSO 

or other instruments certified for aircraft use according to TSO or JTSO or ETSO standards may be installed. Note: Only radios with diameter 58mm (2 1⁄4 in.) can be installed at the assigned place in the console below the instrument panel. Variometer 

Manufacturer Type Certification No.

Winter 5 StVM5 (Diameter 58mm) TS 10.230/14  + 5 m/s Ident.No. 5451 

 +1000 ft/min Ident.No. 5452  + 10 kts Ident.No. 5453 Winter 5 STV 5 (Diameter 80mm) TS 10.230/13  + 5 m/s Ident.No. 5251  +1000 ft/min Ident.No. 5252  + 10 kts Ident.No. 5253 
DG-808C 

6.3

Certification No.

10.241/8 

ed time, outside air temperature, 

mum equipment: 

raft use according to TSO or 

meters, gliding computers or 

led if they do not in themselves, 

a hazard to safe operation. 

nt are to be installed after 

 they will be installed in the 

her places it must be assured that 

connected via appropriately rated 

art should not exceed 3A. 

ce report. 

Maintenance Manual DG-808C 

Issued: June 2005 7.17 List of special tools A Special 13 mm wrench for front tailplane mounting screw (supplied with 

the glider) (W 35). 

B Pin 6 mm diameter with handle for wing tip mounting (W 36) (only with 

option wing parting) 

C Open end spanners 

mm mm mm mm 

7 10 17 30 8 13 19 9 14 22 

D Allen key wrench: 5 mm, 6 mm, 8mm, 10mm, 12mm E Wrenches for slotted nuts (hook spanner) according to drawing W 51 

(encl.) (for the bearings of the upper drive belt pulley) 

F Two steel rods dia. 4 mm (5/32 in.) appr. 70 mm (3 in.) long (aileron 

control stops) 

G Spring balance max. reading 50 N (11 lbs.) H Nicopress tool 64 – CGMP I Hose connector TS 16 (to drain coolant) (supplied with aircraft service 

set) 

J Torque wrench 

Torque range 0 - 150 Nm (o - 110 ft lb) with socket wrench 19 mm (for assembly of the drive belt pulley and the magneto housing of the engine) 

K Torque wrench 

Torque range 0 - 50 Nm (0 - 370 ft lb) with socket wrenches 10, 13, 17, 19 mm and 21 mm (13/16 in.) for sparkplugs and Allen key inserts 3, 4, 5, 10 mm 

L SOLO engine tool set incl. puller assembly for magneto housing 
DG-808C 

7.2

.) 

fugal clutch: Puller assembly for 

wing W40 

tch: Puller assembly for lower 

W60 

 diameter 25 mm (1 in.) appr. 2 

ar PVC hose inner diameter 12 

connector GS12) 

mm inside diameter to test the 

55/1 

gee (bungee for retaining cable) 

Maintenance Manual DG-808C 

Issued: April 2009 TN800/35 8.18 Partlist In this list you will find only parts of the powerplant, the electrical system and control surface sealings and turbulators. 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 

a) necessary for the 25 hours inspection60510806 Spark plugs Bosch W5AC electrode gap 0.5 mm Caution: The removable cap must be secured with a little bit of Loctite 638 on the thread prior to installation 40050360 Spark plug S36 (Bosch W5AC electrode gap 0.5 mm) with screw 

cap fastened to the thread by crimping, marked with a red dot of paint on the insulator 

60507569 Fuel filter elbow or 60507571 MANN-fuel- filter 500009180 WK 31/2(10) 60500150 Gaskets for exhaust manifold (2 pieces needed) 60500142 Air intake filter 70002200 Oil for airfilters with cottonfabric K&N 99-05046 b) Spare parts60510821 Spark plug connector Bosch 0356351032 1kΩ60500127 Nut for spring coupling M 8 for exhaust muffler 60500128 Spring for spring coupling M 8 60502500 Starter motor: DENSO 128 000-1671 12 V 60500155 Gasket for coolant outlet 60504012 Drive belt Poly Chain PC 8MGT 2400-36 with smoothed back 59332050 Front bearing for upper pulley 32205B 59320320 Rear bearing for upper pulley 320/32X 52200054 Securing washer 20 DIN 462 for upper pulley front bearing 30002028 Special grease for upper pulley bearings SKF LGMT3 39001026 Exchange kit nuts and bolts for 400 h overhaul 40050472 Gas spring for ext.-retr. drive S47/2 with Ultra-bush 60000182 Gas strut for muffler frame E1 E1-76-040-130/150N 60505007 Ext.-retr. spindledrive type Stross ATL10 modified with forks 

8M230 and 8M333 

60000330 Rubber mount at engine hinge axis Ultrabuchse 0118288 40872873 Brake pad for propellerbrake (glued to mounting bracket) 60001115 Clamps XO for 6mm bungee (bungee for retaining cable) 
DG-808C 

8.2

10 modified 

150/2 

 mount) 

mount) 

iner against partno. 60504402 

(for automotive fuel) 

p to ser. no. 8-372 

m ser. no. 8-373 on 

K 31/2(10) for refuelling pump 

for primer valve and restriction 

06-0-SL007 

be-resistant 6x1x8 be-resistant 8x2x12 

ves 

uselage) KL-006-0-SL009 

ing) KL-006-2-WR513 

04V27SAH12/00SW

Maintenance Manual DG-808C 

Issued: June 2005 8.38.2 Parts for the electrical system 

60510891 Battery 4E15 6V, 10 or 12Ah equipped with screw - terminals 40876200 DEI-NT-8E620 40876210 Control unit-NT 8E621 60510464 Limit-switch engine retracted and engine extended 164-574 60510484 Manual extension-retraction switch MTG 206 S 60510854 Key switch 3 Pos, 2 Pol KL09-1908KA (Master switch) 60510370 Press-button SECME 07 17801 21 for starter up to ser. no. 8-344 60510372 Press-button DJET 07.17502.21 for starter from ser. no. 8-345 60510375 Press-button 12G2904 for test of second fuel pump and for 

refuelling pump 

60510385 Circuit breaker ETA 2A 60510386 Circuit breaker ETA 3A 60510436 Fuse 535257 60 A for batteries 60510440 Fuse 250V 0.2A 5x20 m for fire warning light 60510550 Proximity switch Insor INCT 1212 40871350 Proximity switch ready assembled with wiring and plug 60510796 Socket BSB 12 (in main bulkhead) 60510797 plug BSK12 for socket BSB 12 
DG-808C 

8.4

rs 

thout glue, curved 

50 m roll glue film 

de, 66 m roll PVC tape 

x 7 m (23 ft.) 

x 1.45 m (4.76 ft.) 

urbulator tape) 

de, 66 m roll PVC tape 

ing) 

m, 33 m roll selfadhesive 

ee 0.4 mm thick 

19 x 30 mm without glue, curved 

(9.2 ft.) 

50 m roll glue film 

de, 66 m roll PVC tape 

long 

eal weatherstrip Cat.Nr.2101 

) 

Maintenance Manual DG-808C 

Issued: June 2005 9.19 Enclosures 9.1 Equipment list 

1 kg = 2.2046 lbs 25.4 mm = 1 in. Note: If this list is not filled out, you will find a similar list in your aircraft logs. Parts of the min. equipment are to be chosen from sect. 6 of the maintenance manual. Subject type 

mass 

kg 

arms 

mm 

date of 

installation 

date of 

removal 

Airspeed indicator Altimeter Variometer el. Variometer Compass Radio Engine Indicator and OAT gauge 

DEI-NT 

DG-808C 

C. G. hook G 88 forward hook E85 Seat harness 
DG-808C 

9.2

work 

nual 

175 200 225 250 275 300 

 was determined shall be entered. 

..h - ..........h 
Zugfederltension spring 

77x58x10,3x1,3 zn 

512513 

65t23J2~ 

.0 

Feder 51 2512 

Halse st2413 

Zugfederltension spring 55x12x1 

6512311 

Seitensteuerung 

rudder control 

BR19~__ , i 4L1313 . 6 

6 ______ _ __ 6, 

. , 

i' 

BR1B 

8LI612 

8L1613 

7 Kugelgriff schwarz! 

ball handle black 

R62/3 

V /7'# 8L1611 

W 

M6 DIN9B5-8 zn 

~"'5135 

iii"> file: e:fII (Dec 

o.Dl 

.. C" 

<-(D e: .. ,,<- (De: 

1'.)2. 

01\) 

5:8 

01 

5125 bJ1 

St31 

WOlbklappensleuerung 

wing flap control 

68t9 

65123 

Quersleuenung I aileron control 

St2 

BR2712 

zur Spornradgabel/ 

towards tailwheel fork 

lY 

! 

! 

i Splintbolzeniclevis pin 

_~ .... ~:,~61~I:~~:~::n . . . . . .. ..... ... 6,4 DIN9021 Stzn 

I Splint 1,5x12zn BR2712 . 

6811 

68t3 

Handsteuer s. Diagramm 1 

/-'~ 

WOlbklappensteuerung 

~ .,,-'/v wingllap control ._, . ~x'>. I :~,L Bst15 

s.DetailX 

Bremsklappensleuerung 

airbrake control 

of> m I: 

,. 

I: m mlO c." "".,. Massekabel 8St11 

6RU4012 

L ." 

z!l! 

~~ 316 

[3 

~g 

.. ~~~ 

o~ 01\) 

... ~ 

~ ~; 

Detail X 

control column see diagram 1 

8St71/1 .~ 

28t514~ 

Z130M 

B817 

A/--···I

, 

6St205 

68113 

Bst12 

2812511 

88t70 

281714 

81211 

6St205 

BSt10B/1 + 12 

Tesaband 651 

30 breit als Sichenmg 

textile tape 30mm wide as securing 

J~\' ~\ Trommelbremse 

for drum brake 

Option Scheibenbremse 

for optional disc brake 

0.0 

iii' iii' 

ecec mOl 

33 

1\)3 

>0 

=1:: 

mm 

a .. ,,-

~.~ cae: 

:02;: 

.,., 

"0"0 

.,"0 "m 

0.1' 

ml: 

"0" co. 

=OJ 

~Cil n3 

om ;t", 

aiil -"0 

iil. "0 

am 

I:/il 

fjtD 

- I: 2'm m2 m" iillO 10 _. 

m3 

!!!. ;tl 

0.1: m3 

"S. 

9:~ ~IO 

iiliil 

33 

",3 

'" 

I\) 
", 

D6-800 

St~/'{t:r"l1g 1m FI(j9~( 

, 0 17 f r" I j i t1 I h ~ W /11 g S 

F{q,UOH ,51ClurUl1fj 

jlarer(Hf cfndrDl 

". CSt)7 

/ 

6Jt 65(1 

((5 tGfl2J 

as(6) 

/(ast ;f) 

/ ~ .. 

/ 

/ 

G.ff1'l/ 

6"Jt65/f 

U j( 65/1-,-~='==,-,, __ 

... ,.' 

("Sf 2!J 

.... 8St28 

~ F 12/ Z 

UF f211) 

8,If 27/1 ",tf 

S,l{(j~~~lt;fO 

'C ___ ~_ 

bl"f)/l 

~~~=+1~fI!fF -fJ/1) 

vr {(}f9 

/ GS( 'tS 

6Ptbl2 

A .. s ~Cc; 

sf", 

6JflfO 

6Jflf(' 

Bf"'MJ klal',eH sicu,,.,,,,'J 

a i ,.. 6 rQ k Co Co", t r 0 { 

AVJga6~ Nov. 1r;,'3 {J.JU .. .(, 

Schleppkupplungen, Wasserballastanlage 

tow releases, waterballast system 

to 

Q.. ~ III 0, ... 'Q. ..:: 0 

~ ..§ ..:: 

~ l> 

11\ 

.~ ... ~ till (I) :!: 

'" 'It 11\ .~ :::c 0, .~ c: 

.~ .5; :a ...... .Q tJ -c 'E 'E .i:! =-- ;~ .!! 

I/) 

.!:; 

11\ I/) 

l> .:.: 

'It ~ ~ ~ ~ c: c: tJ c: .~ ,. 

'" ,. c: ~ 

~ '" Q.. 

tJ e: a ::. ~ 't:J 

i:! 

... E c:: 

::. ~ 

c: 'i\j 0 E Q.. t:o: 

~ Go 

It.. ~ E ~ ..::: tJ l> li i ~ :2 

Li.. tJ . ~ ~ ~ III 

0\ ~ l> 0 

b 

~ V, -c 

~ ~ 

:~ 

Q: 

~ 

llJ 

.~ 

& 

.!e 

tJ 

Is) 

~ 

.~ 

~ 

III 

tJ 

Diagramm 5 

diagram 5 

Ausgabe: November 2004 

Issued: November 2004 
waterballastsystem in the wings waterballastsystem in the fin 

check valve 8F75 (only 75 L bag) 8FE30 

chain-link C 3 mm I 

(.12 in.) II II V j \ \ ~ 

Nylon cord 3mm 

(.i2in.) 

8F71 751; 8F73 601 venJion:Competition; 8F40 SOl version: CIBSSic 

waterbag glued with Silicone onto valve 

wrap 3x Tesaband 651 at the 

PA tube Bx1x730_ 

ventilation " 

place for the hose clamp around waterbag 

hose clamp 25-20 

dump valve drive at fuselage 

dump valve in wing compression spring O,75x9x50 i=11 

niPPle23B~jUstingscrewM6 

fuselage 

\,A;J II 2R1111 

~p;,;~~' ;';ri~g'1, 1x9,6x62 i=10 1.4310 

tow releases 

waterballast control handles in front cokpit 

fin tank 

BR24B11 with optional nose tow release without nose tow release ;::W_20IlA 

~ nippel27D 

shift handles Suntoul 

all dimensions in mm; 25,4mm= 1in. 

-, 

PVC tube 12x4.5 

with webbing 

PVC tube 12x1.5 

tube dimensions 

(inner diameter x thickness) 

diagram 5a 

i~sued April 2007 

AMBOO-17-07 

waterballst system 

tow releases cable dia.1 ,6 mm MIL-W-83420 If A 

Abnahmen tar den statischen Druck I 

probes for static pressure 

Rumpfschale I Sitzwanne I seat shell -'----'--- shell 

Wssserabscheider I 

water precipitator 

analog zu Stat h I 

similar to Sta. h 

)(6~3712 in Unterseite Rumpfspitze I 

probe 6R3712 below fuselage nose 

Seitenflosse I fin 

TE Pitot 

~~: I probe IZJ 

spazi.1 TE DOse 43 . ~~ . S lS tspecial TE probe , 

-·-·-b--·-·-·-·-"j~;·1 • geschl~ I closed 

Multi DOse ist Option, serienmaBig Adapter SQs tor,'normale TE- DOse 

Leihmgen Pilot M und stat. M entfallen " ( ( 

Multi probe is optional, standard is adapter SP5(fo,t normal TE probes 

lines Pilot M and stat. M are not . 

----, 

AusgleichsgetaBe unter 

der SauerstoffflaschenrOhre f 

for variometer flasks below oxygen botHe housing 

VVichtiger Hinweis: Der Fahrtmesser dart nur an den vorderen Druckabnahmen Stat V + Pilot V angeschlossen werden. I 

Caution: The airspeed indicator must be connected to the front probes Stat V + Pitol V. 

Die Anschlusse der Multi Duse sind zum AnschlieBen von Variometer- und Rechnersystemen bestimmt I 

The multi probe is intended to connect variometers and gliding computers. 

Aile Schltuche PVC weich 8x1 ,51 all lines soft PVC 8x1,5 

c~ > G>cn~ 

I 6f m 

~3'fil COm::J 

00'2: ~ ~ 

i&i& 

!:!: !:!: 

"m 1Ilg. ::Jm o.::J 

-c: o ::J 

!!to. 

"tIO Cilm 

mm mill 

c: 3 

Cils: 

2 

~ 

1ir>Q,g 

cnc:m m c:mlO lO 

~'gD1m .. C" 3 3 

;:!I! '" 3 

Ill;: '" '<Ill 

.., _. 0.., 

00 

<no <n 
Tyre pressure 29 psi 

above tailwheel 

Reifendruck 3 bar 

Tyre pressure 47 psi 

on the right wheel door front 

Drainer on the right wheel door 

rear

placards DG-808C Classic 

diagram 7a 

issued August 2005 

13 

10 11 

12 

zu Brandhahn auf 

closed fuel cock open 9 

14 15 

16 17 

18 

20 L 8 5 0 –5 –10 -14 

19 

Option near the switch 

Flügeltanks

wingtanks

fuel pump

test 1 

5 Fire 

2 Primer 

auto 

off

6 

4 stat

TE 

man. 3 

7 

on the left wheel door front 

Sollbruchstelle max. 6600 N 

rated load max. 1455 lbs. 

8 Propellerbrake

25 

intern

off 

extern

22 

FLIGHTLOG 23

5. All controls and knobs in reach ? 

6. Altimeter ? 

7. Dive brakes cycled and locked ? 

8. Wing flaps in take off position ? 

9. Positive control check ? (One person at the 

control surfaces). 

10. Trim ? 

11. Canopy locked ? 

Additional checks before self launching 

12. Fuel level ? 

13. Fuel Cock open? 

14. Canopy open – propeller clear ? 

15. After starting the engine – close canopy. 

16. Check engine RPM. 

17. Check both ignition circuits.

Altitude in [m] 0-3000 4000 5000 6000 7000 8000 

VNE IAS km/h 270 256 243 230 217 205 

Altitude in [ft] 0-10000 13000 16000 20000 23000 26000 

VNE IAS kts. 146 138 131 124 117 111 

on the instrument panel

21 Starter

Throttle

26 

Reifendruck 2 bar 

Tyre pressure 29 psi 

above the tail wheel 

12 V near the 

socket

Typ: DG-808C 

W.Nr.: 

fire proof placard at the 

main fuselage bulkhead 

Bauteil Nr.: 

part No.’s at all components 

Benzin min. 95 Okt. Zweitaktöl 

petrol min. 95 ROZ 50:1 two stroke oil 22l 

screen print near the fuel filler

Reifendruck 3 bar 

Tyre pressure 44 psi 

on the right gear door front 

Drainer at the left gear door 

rear

placards DG-808C Competition 

diagram 7b 

issued August 2005 

Tankpumpe

Refueling pump 

at the main fuselage 

bulkhead 

near the button 

13 

10 11 

12 zu Brandhahn auf 

closed fuel cock open 9 

14 15 

16 17 

18 

20 L 8 5 0 –5 –10 -14 

19 

Option near 

the switch 

Flügeltanks

wingtanks

fuel pump

test 1 

5 Fire 

2 Primer 

auto 

off

6 

Gepäck max. 15 kg 

baggage max. 33 lbs.

at the main fuselage bulkhead 

Vario 

Radio 

XPDR 

Gyros

4 stat

TE 

man. 3 

7 

Sollbruchstelle max. 8250 N 

rated load max. 1820 lbs. 

on the left gear door front 

8 Propellerbrake

25 

intern

off 

extern

22 

FLIGHTLOG 23

Altitude in [m] 0-3000 4000 5000 6000 7000 8000 

VNE IAS km/h 270 256 243 230 217 205 

Altitude in [ft] 0-10000 13000 16000 20000 23000 26000 

VNE IAS kts. 146 138 131 124 117 111 

on the instrument panel

24 

DG Flugzeugbau GmbH 

type: DG 808C Competition serial no: 8- 

year of construction: 

Maximum airspeeds km/h kts. 

Winch launch 150 81 

Aero-tow 190 103 

Manoeuvering VA 190 103 

Rough air 190 103 

Max. flap extended speed +8° +5° 190 103 

Landing gear operating 190 103 

Maximum speed VNE 270 146 

Max. flap extended speed L 150 81 

Powerplant extended 190 103 

Powerplant extension-retraction 100 54 

Approved aerobatic manoeuvres ( only without waterballast and 

with engine retracted) 

pos. Loop, Stall Turn, Lazy Eight, Chandelle, Spin 

Maximum mass: 

18m wingspan 600 kg ( 1323 lb.) 

15m wingspan 540 kg ( 1190 lb.) 

Loading chart 

Cockpit load ( parachute included ) 

maximum 110 kg 242 lbs

minimum kg lbs

With lower pilot weight necessary ballast must be added. 

limits for use of the fin or fuselage waterballast tanks 

°C 13.5 17 24 31 38 minimum 

ground temperature °F 56 63 75 88 100 

m 1500 2000 3000 4000 5000 maximum flight altitude 

above GND ft. 5000 6500 10000 13000 16500 

Preflight inspection 

1. Lead ballast ( for under weight pilot )? 

2. Fin ballast tank emptied or correct amount 

filled in? 

3. Parachute worn properly ? 

4. Safety harness buckled ? 

5. Seat back and pedals adjusted ? 

6. All controls and knobs in reach ? 

7. Altimeter ? 

8. Dive brakes cycled and locked ? 

9. Wing flaps in take off position ? 

10. Positive control check ? (One person at 

the control surfaces). 

11. Trim ? 

12. Canopy locked ? 

Additional checks before self launching 

13. Fuel level ? 

14. Fuel Cock open? 

15. Canopy open – propeller clear ? 

16. After starting the engine – close canopy. 

17. Check engine RPM. 

18. Check both ignition circuits.

21 Starter

Throttle
Triebwerk 

powerplant BM251 

,,~;~~~ M6x22 DIN 7984 

Diagramm 8 

diagram 8 

BM252/1 M6x20 DIN 912 - B.Bzn 

MBx16 DIN 912 - B.6zn 

V'Y·'\4~I-e-~~BM25212 

siehe Zeichnung BM110 :----+~\-

see ",Q'W" "'. 

62 

BM269 

BM115iff~~~~:rIl--M_!IDIN Zahnriemen 

drive belt JlL~~M BM13B 

::: Jl----RR12811 

Rundlager Typ A 

rubber mount 

KOhler KTM VWO095 

radiator 

BR12811 

M6 DIN 9B5.B 

SchnittA-A , 

BM169 BM171 i 

Rundlager Typ B ;--- _ 

rubber mount 

5'3DIN125~_ M5X55LN9037', 

M5SSN003 M5DIN9B5-8.6zn ~~', ' ~';~'!j~ __ - BM254 

Anlasser 

starter motor 

BM229/1 ohne BBSA Kupplung 

with BBSA clutch 

BM22912 mit BBSA Kupplung 

without BBSA clutch 

Propeller Bremsen 

BM276 

Ausgabe August 2005 

issued August 2005 

KOhlsystem DG-808C 

Coolant system 

Vorderansicht: 

front view: 

5 

Schlauch 4 langs 

aufgeschnitten 

und aber Nr.1 

als Scheuerschutz 

an ZOndbox mit 

240 

Tyrap 4,8x190 @ 

befestigt 

hose 4 cut langswise 

and slip over Nr.1 to 

prevant chafing 

fix at ignition 

box, with 

Kahler 

radiator 

KTM 

VW0095 

engine 

Solo 

2625 

tyrap 4,8x190 6 

Alu-Rohr 16x1x60 

tube GS16 

o 

Diagramm 9 

diagram 9 

Opel GM 08-26888 8974835 

o 

@ L=60 

KOhlerverschluB 

radiator cap KTM 4.9090.01 

KOhlwasserauslaB 

cooling water outlet 

8M251 

3 

8 

8M253 8M252 

KOhlwassereinlaB 

cooling water inlet 

® 

_---'"r-Wasserpumpe 

waterpump Webasto U4810 

Ausgabe August 2005 

issued august 2005 
m 

boll M 1 OX60 LN9037 it 

nul Ml0 DIN9B5-a ZN :J 

washer 2x 10,5 DIN125 SI zn (with BM233/1 up to issue g) !!!. 

wash 10,5 DIN125 SI zn (with BM233/1 issue hand BM333 see TMBOO 35) g 

, 

bon M6x90 DIN931-B.8zn gas slrul S4712 b II MBx50 DIN 7984 B 9z bo M6x14 DIN 79B4 B,9zn i[ nul MB DINBB5-B zn 0, n iil 

washer 6 4 DIN9021Stzn nut MB DIN 9B5.B zn Sl 

~ , l'l;L~~~~d::l~~~~w:aS:h~e:r:B~'4~D11:N~I:2:5~S~I~zn~~~~~~~::::::~~==r;g. c: 

:J 

bollM6x25 

DIN7991-a.B zn 

nulMB 

DIN9B5-azn 

w8sher6,4 

_ !P.. ;::::;.: 

DIN9021 Stzn ~ \ 

boll M6x25 \ \ : 

DIN7984-B.B zn 

nulMB 

DIN9B5-azn 

washerB,4 

DIN9021 Stzn 

gr securing washer 5i 13 DIN 432 SI 

Co 

~ ~ 

'" BM254 

ser. no. 

boll MBx45 LN9037 

nul MB DI N9B5-B ZN 

washer 2x B,4 DIN125 51""n 

up 10 ser. no. 8-402, 

ser. no. 8-404 up to 406 an, 

BM122 \/\IIlh B~33/1 issue h as spare pi 

, ' 

spindledrive Slross ATL 10 

BM1B4 

BM230 

boll M12x55 DIN 931-a.B zn 

nul M12 DIN 9B5-B zn 

washer 2x 13 DIN 125 SI zn 

ser. no. B403 and ser. no. B407 up to 409 

and from sar. no. 8-411 on Q. 

instead of BM233/1 and boll MBx45 r2j' 

o 

o 

co boll MI2xl,5x90DIN960-B.Bzn 

up 10 se no. B402,. ser. no. B404 

UPI0406~nd8-410. (sTeTNB00-35) 

.f------1 ··~M23311 issue h 

BM333~. ____ \------

-~ ~ 

o 

~ 

u~ ~l~~ ~~~ j!!S~1!! 

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~~~ I!! l~i 0 00 ~3 Q.a, 

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: ~~5 ~ ~i I 0-" 5 3! 1It.!l! ;;)~[ ~ ::::J I~ Ii ~ nO>" 5 ~~ O;!'ili 

! ~~l i ~.~ iii" if 01 iii I'D • ~i ~ !>C g: ::: 11 liRii. <C :: il ~ ~ mg (J) __________ :t __ ~m 

• ~ IC:~_ ~~ i a,g_m,. ~ 85 - t -0>" • 

m ? 

~ !!!. , !fl - .. rn ~ '< 

I[~!f ~ 0 rn 

m ~ Q,,~ 

~ ~H~ .~~ 3 ~-"o"~l! 8l'ii'1II 

.. ~a~ ·8~~~ ~izm W '~I ,~~ N rfl3 ~ Ii'"! ':!>.a: ..... "'C 3 8;- ...... ::::I o~ I iifi'o 1~~F3= i·~ ~ i~$~ 6 , ~ iI"i ~ &i,b':" N t ~ ~~ ~~h .. """' " .. , r ~9:g 

ifi~ftfl~ ~i§i m ';'31 .. ~ m § In i Uf I:cclll.,cn m[ ~ u" '< i5~ B ~ 

mm~ii ~t itt: ~i ...... z /z -Ii ~~i ~ ~ .,9z/; ~i. ~~~t;;t!~~ <: •• ~ :t i H ~!!J!!JQ: ii ...... 11:) a ~, • "Ii 

iir» se~ .. <~ ~ ~ 11 i! ! 

~ I~ If --~~~~~ ~ ~, i rn'" :::J":::J"f - ~2..".ii! 3 -g c:rn ii ~3~::::~ g N 

~ / 5 (J)<C !l.!l.~ 3~"181 Coil) ~~.a ~~ 2:~ • ! t. ...... & !!!: 

<-"" (Q - ~ iii HI ~ 3 ~ c:(J) ;;:i s- ::::J<- ill .~ m (J)C: 8 0 3 .~ ItiliNfi?' l~OQ 0 

f\.) ::!. [~ i 8" 3 " fl· iii" 

01\) ~~. "Ii <C 

00 ,~ 

-~ ~~ iil 010 g~ m ~. 

01 3 ~CI .~ 

~ if il f~ ~f 3 ii".a iii ~ 

'Iil- !~ ~, ~ ~ 
DG-808C 

Einbau des Kraftstoffilters 

Installation of the fuel filter 

E 

E 

a 

..,. 

!'i 

Diagramm 11 C 

Feder VD-206 G-02 

spring 

Ty-rap 186x4.8 

Ty-rap 186x4.8 gegen 

Verrutschen des Filters 

in der Halterung 

to secure the filter in the 

holder 

Filter gerade I straight 

Die Schlauchlangen sind gleich fOr beide Filter 

the length of the hoses is the same for both filters 

<;g 

0< X; 

<;g 

0< 

<;g 

a c-

~ 

"---

6 X 0< X; X ~ 

Z S>"' 

~~~ ~ 

Filter 90· abgewinkelt I elbow ~ 

/ X; 

9< 

O< 

:x ><: X; 

r="\ 

\J 

Ausgabe Juni 2005 

issued June 2005 

DG-808C Diagramm 11d 

Kraftstoffanlage mit FACET Betankungspumpe I 

fuel system with FACET refuelling pump 

Serienwraion flItandard YenIion (bel Option FJOgaltanks alaha BEP210 

with optional wing tanks &eEl 8EP21 OJ 

,------------------------------, 

i Filar MANN 500009180 i 

: Vv'K 3112(10) Batankungspumpal 

i !refuelling pump I 

: ElnfQlllw lung Facet 60106 

:fillercou ing I KL 006-2 LOO7 

Tankstulzen 

fuel "liar 

aRlO 

35 

, 

Tankdeckel 

"Iler cap 4R87 

EW6x1-R 118 

Cnllllftungsieitung 

Nyloorohr 6x1 vent line 

nyIonhoee ex1 

Luflfilter 

KndbIlDffverlBiler mit Primervenlil air intake filler 

mulll-fual-oonnactor with pr1mar-vaIYa 

(8M30B/2) 

BM307/1 

l1ctI~~nI 

my 

Filter-QG Nf. 80507569 

:~~sOODomo WK311210) 

Y 

1.':""""""'" 

110 

1300 

v"'_ 

carburettor 

Ringnippel881.0304 

rlngnlppel 

-~ Rumpf 

""'''' 

Tank 

fa" 

8R144 F:WJ:g~08 

,-__ 4R3_W~'.\ 605\1 1100 

4R4D11 ANQ14-1D , , 270 , Schnaldrtng 

GOIzdSLl. Krafbiloffpumpe OberwurfmullBr 300 fuel pump GOIzmSLl. Facet40108 5R200I1 

I comprussion-typa 

Drainer CAV 110 .. ", , 350 , 9IlO 

, Kmftstoffschlauche I fuel hoses:'::::~~=J4'JC:~ PU hydroly8e und mikrobenbealandig 1 PU hydrolyse and mla'Obe resI!Itant 

ex1,5X9 ex1,5X9 

KXXXXXX3~ 

wie gelief8rt 1 mil Melallgellechllhrzogen f 

a& delivered with metal shield 

"",12 

Brandhahn KH 1072T - T I/A 

mit Gewindel:llile 114"-9 W!Irth 06Q94914 (AUllllllngewinde) 

und GewindIJIOlia 1f4"-8 W!lrth 06995914 (Innangewlnde) 

emergency shut off valve with hose connectors 

VerbindunCJBStC!cke und Klemmen 

Fitlinas and damDB 

8 WinkelstClc:k VllSAG 08 1/8" Messing {elbow, brass 

t FacetEinllCl1raubstutzen41199/nippie 

u Nlpppal SAG 06/R1/8" 1 nipple 

m I1lter 8chrumpf8chlaucl1, 30mm I~ f rad heat shrink wbi~ 

n blauer 8chrumpfllchlauch, 30mm lang f blue heat shrink wblng 

w Ohrklemme 1131 clamp 

x Schlauchschelle 87011 (919) f hose damp 

y Schlauchschelle 87012 (11/9) I hose damp 

z Schlauchschelle 870f3 (1219) f hose damp 

Ausgabe April 2007 

issued April 2007 

AM 800-17-07 
iii· » 

1111:: 

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4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

24 

8RU7 8R93/2 

Lenkbares Spornrad mit Nadellagern 

steerable tail wheel with needle bearings 

DG BOBC 

:~~ I ~ 1_11 

Nadellager NA4903 (needle bearing) 

Innenringe mit Loctite 638 auf 8R94 verklebt (inner rings secured with Loctite 638 to 8R94) 

Nadellager NA4903RS (needle bearing) 

WC18DU 

Splintbolzen (clevispin) 

6x18/15 DIN 1434 

8R93/3 

Dichtung 

5.3 DIN125 Stzn 

M5 LN9348 

DU-Schicht unten 

(Einbau vor Montage der 

Innenringe Nadellager) 

DU-coating on lower side 

(install prior to inner rings 

of the needle bearings) 

4R25 

Z162M Zugfeder (spring) 

Seitenruderseil 

rudder cable 

Reifen 20Ox50 

lyre 

Kugelgelagertes 

Spomrad S23 

hub with 

ball bearings 

4R89/1 

DUCATI-Zilndanlage ISKRA..zOndanlage 

IOUCATI·Ignltion svstem) (ISKRA.Jgnltlon svstem) 

Schraube (bolt) MS ... 12 DIN 912-8.Bzn Schraube (bolt) MB.12 DIN 912-8,8zo 

Scheibe (washer) 8.4 DIN 125 Stzn Scheibtlwash~£>- 8,4 DIN 12551 zn 

~ 

RM275/3 

Sc:hraube (bolt) M8:><25 DIN 912-8.8zo Schraube (boll) MB~30 DIN 912-8.8zn 

6,4 DIN 125 Stzn 

6,4 DIN 9021Stzn 

Splint 1,5x12 DIN 94 

splitspin 

S23 

4R89/2 

//~~~ ·0/ 

4R89/1 

Scheibe (washer)8,4 DIN 125 Stzn Scheibe (washer) 8,4 DIN 125 51 zn 

Buchse bush B M 277 Buchse bush 4 M 16/2 

Splinlbolzen (clevis pin) 6)(16 ... 3,5 DIN 1434 Stzn '-.. iffi?iJ<;-// 

Scheibe (washer) 6,4 DIN 125 51 zn 

S lint solit Din 1,6)<10 DIN 94 

BM27912 

8M2BO 

--

-- Schraube (boll) M6x35 DIN 931-B.Bzn 

Scheibe (washer) 6,4 DIN 125 51 zn 

Mutter (nul) M6 DIN 934-8 zn 

Gummiseil rubber band) ",2mm, 6-fach 

Schraube (boll) M4,16 DIN 933·8.8 SI zn 

Buchse (bush) 8M74/3 

Schraube (bolt) MBxi0 DIN 933-B.8zn 

Kepf auf Hohe von 4,5mm abgedreht 

bollhead turned d0'M110 4.Smm) 

Schraube (bolt) M6x30 DIN 9i2-8.8zn 

~Xu~t~~~~~di;~~~e~:~~:nDIN 125 Slzn 

Stellschraube ad'ustment screw M6x20 /20 

Mutter nut M6 DIN 936-8zn 

Klemmnippel set screw clamp) 2-37 6x13 

Bremsbelao brake Ifninol BM277/2 

Identfsch (identical) 

BM27911 

BM273 

BM27811 

Schraube (bolt) M6K16 DIN 912-8.8zn 

ScheibEU..washe!L6,4 DIN 125 Slzn 

Schraube (boll) M4x16 DIN 933-B.Bzn 

Scheibe (washer) B,4 DIN 9021 SI zn 

Buchs. (bush) B M 7413 

Zuafeder lension sorinQ) 1,2x9)(16 

Schraube (bolt) M4,16 DIN 933-!l.Bzn 

Scheibe (washer) B,4 DIN 9021 SI zn 

Buchstibus11LB M 7412 

Schraube (bolt) MBx12 DIN 912-B.8zn 

Scheibe (washer) 8,4 DIN 125 SI zn 

identlsch (identical) 

identisch identical 

idenlisch idenlical 

idenUsch Identical) 

Bremsbela brake linin BM275/2 

Anmerlnmg: Anstelle des 

~. " J; .,. 

~ e -Cl"" -", 

§~ 

::r. " 

~ 

2-

Ti 

Bremsmalor {Progetlerbrake malor}: Bremshcbels 8M275/J kann cin ~ <:-

~ f 

1iJ Ictirzerc Hebel 8M287/1 mit 16 Schraube (boll) M3~16 DIN 84 MS 

~)(U~I~~~~)(~~~~e;1:.~~IN 125 MS verschraubtcm Belag 8M287/3 

verwendel werden. Der ~i 17 Schraube (ball) M5)(25 DIN 7984-B.Bzn Splintbelzen 3 is! von vorn nach Scheibe (washerI5.3 DIN 125 SIzn 

lB Schraube (batt) M5",25 DIN 912-8.Bzn hinten ZU lUOnUeren. Scheibe (wa5he~1· 5.3 DIN 125 Slzn Note: Instead of the brake lever 19 Lothulse soldered cap) M4 8M275/1 a shorter lever 20 Gabelkopf fork end M4 

21 Bawdenzughulle 05mm mit Teflonlnnenhulle 8M287/1 with screw on brake Jlrems"'otor Bomen outer 05mm plaled inside with teflon pad 8M287/3 may be used. The 22 BowdenzuQ IbalNden inner 01.5mm split pin 3 must be installed 23 Halteruno bracket BR212 from Ule front. 

'Propellerbrc<k. Motor 

Zeichnung fOr ISKRA-Zundanlage (Drawing for ISCRA-ignition system) 

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