The Glaser-Dirks

DG-400 Self-Launching Sailplane

A Pilots Introduction

and Orientation

By Pete Williams

First Right 1 May 1981 Total Built 290 Engine 43 hp aircooled Rotax 505 2-stroke

8th Printing 72004

copy 2000 Pete Williams 1033 Dresslerville Rd Gardnerville NY 89410

Tel 775-265-3877

Cover DG-400 taxis to parking spot after landing as a glider at Glendale AZ Airport Haas photo

2

Introduction

The information contained herein is a compilation of operational and maintenance procedures and problems gleaned from both personal experience and feed back of data from the Glaser-Dirks factory as well as other DG-400 pilots throughout the world It is by no means comprehensive or complete nor is it meant to replace any procedure found in the factory manual s

From personal experience I have found that owning and tlying a self-launching high performance sa ilplane with a retractable motor to be most rewarding There are definitely two disciplines involved The first of course is the discipline that goes with flying a pure sailplane This includes the search for lift climb and cruise optimization weather factors and the ever present possibility of not finding lift While landing out appears to be so lved by the availability of the motor it becomes quickly evident that the very presence of a retractable powerplant changes the way a soaring pilot conducts each flightThis new discipline has to be learned as you are now a sailplane pilot and a tow pilot The bottom line is there are more decisions to make in the cockpit of a modern selfshylauncher Decisions such as at what altitude above gro und should the engine be extracted when low or what to do if the engine does not start Couple these decisions with the fact that once the engine is extracted soaring performance drops drastically and it becomes very important to get the engine started as quickly as possible Add to this the respons ibility for periodic maintenance of the engine it s retraction system the electrical system the fuel system and propeller and you have quite a bit more to think about and do when you become the pilot of this type of sailplane So you really become two pilo ts and have to shift gears between the two disciplines quic kly and efficiently

Is it worth it I believe it is because with the best of both world s you now have a new found freedom to launch when and where you desire and go where the lift is Yes more time will be spent servicing and maintaining the engine Yes your cruise band will be narrower since the engine must not be extracted at tree top level But once these disciplines are mastered you can enjoy soaring from a vantage point far removed from sail ports tow planes and wing runners Flight safety is no accident and the SLS pilot has to do quite a bit more homework than his purist brother Hopefully this manual will provide some insights into what it is like to fly the DG-400

3

DG-400 SPECI FICA nONS Wing Spans 15M492ft 17M558ft Fuselage Length 229 ft

Wing Areas 1076 ft2 1138 ft2 Aspect Ratios 225 2734 Empty Weights 6746 Ib 6834 Ib Max Weights 1058 Ib 1014 Ib Water Ballast 90 Iiters24 US gal

Max Wing Load 98 Ibft2 891 Ib ft2

PERFORMANCE (STD Conditions Sea Level Hard Surface No Wind Max TOW)

15M 17M VNE (Never Exceed) 146 kts VSI (Stall) 4 I kts 38kts Min Sink 134 fpm48 kts 118 fpm47 kts Max Glide Ratio 42 I 45 I Takeoff Run 754 ft 558 ft Climbing Speed 49 kts Max Climb Rate 600 rpm 700 rpm Distance over 50 Obstacle 1007 ft 886 ft Power Loading 246 Ib hp 236 Ib hp Max G Loads +53 -265 Flap Positions (Degrees) -4-8-10 +4 +6+8+12 (Landing) Approved Maneuvers StallSpinInside LoopChandelle

Lazy EightStall Turn

DG-400 in soaring flight near Minden-Tahoe Airport Minden Nevada USA Photo by Sonja Wenger

4

Flying the DG-400

If you are no stranger to soaring a high performance sailplane then you will be right at home in the cockpit once the engine is stowed Roll rates are crisp in the IS-meter mode and a little slower with the 17- meter tips If you have less than 100 hours in glass ships you should have some instruction in a Janus Twin Astir or Grob 103 Use I 12 spoilers out to simulate engine extended and not running Practice landing approaches this way leaving the spoilers deployed all the way to touch down You will discover your radius of action around the landing field to be close and high

Check Lists Read the handbook and maintenance section and make a series of checklists that cover every aspect of engine operation Do not expect the starter to crank every time you want to start and be ready to dive to over 80 kts to get a windmill start Check your ignition rpm drops carefully No drop on one circuit and engine dies on the other may mean one ignition circuit is defective It is possible for the forward underbelly to touch the ground on a high rpm turnup If this happens EASE the throttle off to keep from banging the tailwheel on the ground with possible damage to the tail wheel steering fork Do not launch unless both ignition circuits check correctly

Taxiing It is a long reach to engine control switches so position yourself accordingly When taxiing you will have to alternate your left hand between the throttle and the spoilerbrake handle Do not taxi too fast About 2 000 rpm seems to be right with 3000+ rpm needed to get moving The flap handle can be used as a brace to hold the spoiler handle back when you need to set the brake while stopped

Takeoff Do not forget to set -4 flaps before applying power and double check the spoilers are LOCKED DOWN Safety pinning the spoiler and aileron connections is a MUST Apply +6 flap for liftoff You can get airborne on-4 flap setting but it takes a lot of up elevator After applying takeoff power rpms should be at least 6000 Watch the airspeed build As it passes 40 kts place flaps in +6 and rotate the aircraft as the airspeed needle hits 49 kts There may be a tendency to exceed 49 kts Adjust trim Watch the tach and keep it below 6200 rpms with attitude correction on the stick If your airspeed fails you can climb right at 49 kts by adjusting the pitch of the aircraft to maintain 6000 rpm on the tach

5

Flap and Trim Settings At speeds above 80 kts quite a bit of forward trim will be required making necessary assisting the trim system by applying forward pressure with your ringer on the trim indicator green flag while setting the trim forward on thestick control to lock in the new setting Thermal trim setting seems to be optimized at +8 and LI can be used if the thermal is powerful Speeds slower than 50 kts when in a thermal will not result in an optimum climb rate At high gross weights 55-60kts provides a good measure of aileron control and a better climb rate The DG-400 will climb very well in light lift at the +4 setting especially in the 17- meter mode With 15- meter tips light lift climb performance is less than optimum In fact the aircraft seems to be at its best in all fight regimes with the 17- meter tips installed

Landing with Engine Extended and Stopped To simulate engine failure on takeoff consider at least 500 feet agl as the MINIMUM altitude you would attempt to turn back to the runway for a downwind landing with the engine extended and stopped Deploy full landing flaps to keep your stalling speed as low as possible KEEP THE NOSE DOWN and maintain a minimum indicated airspeed of 55 kts preferably higher Do not flare out high Take the ship right down to the deck for a smooth round out Full stall is not advisable in this condition so a slight main gear first touchdown is preferred to slamming down on 2 points You will not have a lot of time to retract the engine after fai lure on takeoff so it is best to not mess with itYou can use the EMERG retract which will most likely result in damage to engine doors and prop A good rule of thumb is never fiddle with the engine unless your wings are level Never try to start the engine below IOOOagl CEASE ALL START EFFORTS below IOOOagl and concentrate on landing

Landing with Engine Extended and Running The ROTAX is not an enroute cruise engine except to execute a landing with engine out and running Make the downwind leg at partial throttle to indicate about 60 kts and clear the engine at full throttle now and then to keep the plugs from loading up You will find the pattern normal in all respects and need to idle the engine just prior to touchdown Remember that it will take more brake to stop with the engine running at idle

Ground Operations You will find things go better if you select -8 flap immediately after touchdown to maintain lateral control and keep the wings level In the pure sailplane mode retract the spoilers after touchdown to retain rolling energy for the turnoff This is especially tru~ when landing on hard surface fields You must offset the bird on the taxiwaylrunway to keep the wing tip from striking the lights Keep the wingtip wheel on the pavement at all times if operating from a paved strip Taxiing with the canopy open is possible but is not recommended as this can damage the canopy support bracket

6

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

First Right 1 May 1981 Total Built 290 Engine 43 hp aircooled Rotax 505 2-stroke

8th Printing 72004

copy 2000 Pete Williams 1033 Dresslerville Rd Gardnerville NY 89410

Tel 775-265-3877

Cover DG-400 taxis to parking spot after landing as a glider at Glendale AZ Airport Haas photo

2

Introduction

The information contained herein is a compilation of operational and maintenance procedures and problems gleaned from both personal experience and feed back of data from the Glaser-Dirks factory as well as other DG-400 pilots throughout the world It is by no means comprehensive or complete nor is it meant to replace any procedure found in the factory manual s

From personal experience I have found that owning and tlying a self-launching high performance sa ilplane with a retractable motor to be most rewarding There are definitely two disciplines involved The first of course is the discipline that goes with flying a pure sailplane This includes the search for lift climb and cruise optimization weather factors and the ever present possibility of not finding lift While landing out appears to be so lved by the availability of the motor it becomes quickly evident that the very presence of a retractable powerplant changes the way a soaring pilot conducts each flightThis new discipline has to be learned as you are now a sailplane pilot and a tow pilot The bottom line is there are more decisions to make in the cockpit of a modern selfshylauncher Decisions such as at what altitude above gro und should the engine be extracted when low or what to do if the engine does not start Couple these decisions with the fact that once the engine is extracted soaring performance drops drastically and it becomes very important to get the engine started as quickly as possible Add to this the respons ibility for periodic maintenance of the engine it s retraction system the electrical system the fuel system and propeller and you have quite a bit more to think about and do when you become the pilot of this type of sailplane So you really become two pilo ts and have to shift gears between the two disciplines quic kly and efficiently

Is it worth it I believe it is because with the best of both world s you now have a new found freedom to launch when and where you desire and go where the lift is Yes more time will be spent servicing and maintaining the engine Yes your cruise band will be narrower since the engine must not be extracted at tree top level But once these disciplines are mastered you can enjoy soaring from a vantage point far removed from sail ports tow planes and wing runners Flight safety is no accident and the SLS pilot has to do quite a bit more homework than his purist brother Hopefully this manual will provide some insights into what it is like to fly the DG-400

3

DG-400 SPECI FICA nONS Wing Spans 15M492ft 17M558ft Fuselage Length 229 ft

Wing Areas 1076 ft2 1138 ft2 Aspect Ratios 225 2734 Empty Weights 6746 Ib 6834 Ib Max Weights 1058 Ib 1014 Ib Water Ballast 90 Iiters24 US gal

Max Wing Load 98 Ibft2 891 Ib ft2

PERFORMANCE (STD Conditions Sea Level Hard Surface No Wind Max TOW)

15M 17M VNE (Never Exceed) 146 kts VSI (Stall) 4 I kts 38kts Min Sink 134 fpm48 kts 118 fpm47 kts Max Glide Ratio 42 I 45 I Takeoff Run 754 ft 558 ft Climbing Speed 49 kts Max Climb Rate 600 rpm 700 rpm Distance over 50 Obstacle 1007 ft 886 ft Power Loading 246 Ib hp 236 Ib hp Max G Loads +53 -265 Flap Positions (Degrees) -4-8-10 +4 +6+8+12 (Landing) Approved Maneuvers StallSpinInside LoopChandelle

Lazy EightStall Turn

DG-400 in soaring flight near Minden-Tahoe Airport Minden Nevada USA Photo by Sonja Wenger

4

Flying the DG-400

If you are no stranger to soaring a high performance sailplane then you will be right at home in the cockpit once the engine is stowed Roll rates are crisp in the IS-meter mode and a little slower with the 17- meter tips If you have less than 100 hours in glass ships you should have some instruction in a Janus Twin Astir or Grob 103 Use I 12 spoilers out to simulate engine extended and not running Practice landing approaches this way leaving the spoilers deployed all the way to touch down You will discover your radius of action around the landing field to be close and high

Check Lists Read the handbook and maintenance section and make a series of checklists that cover every aspect of engine operation Do not expect the starter to crank every time you want to start and be ready to dive to over 80 kts to get a windmill start Check your ignition rpm drops carefully No drop on one circuit and engine dies on the other may mean one ignition circuit is defective It is possible for the forward underbelly to touch the ground on a high rpm turnup If this happens EASE the throttle off to keep from banging the tailwheel on the ground with possible damage to the tail wheel steering fork Do not launch unless both ignition circuits check correctly

Taxiing It is a long reach to engine control switches so position yourself accordingly When taxiing you will have to alternate your left hand between the throttle and the spoilerbrake handle Do not taxi too fast About 2 000 rpm seems to be right with 3000+ rpm needed to get moving The flap handle can be used as a brace to hold the spoiler handle back when you need to set the brake while stopped

Takeoff Do not forget to set -4 flaps before applying power and double check the spoilers are LOCKED DOWN Safety pinning the spoiler and aileron connections is a MUST Apply +6 flap for liftoff You can get airborne on-4 flap setting but it takes a lot of up elevator After applying takeoff power rpms should be at least 6000 Watch the airspeed build As it passes 40 kts place flaps in +6 and rotate the aircraft as the airspeed needle hits 49 kts There may be a tendency to exceed 49 kts Adjust trim Watch the tach and keep it below 6200 rpms with attitude correction on the stick If your airspeed fails you can climb right at 49 kts by adjusting the pitch of the aircraft to maintain 6000 rpm on the tach

5

Flap and Trim Settings At speeds above 80 kts quite a bit of forward trim will be required making necessary assisting the trim system by applying forward pressure with your ringer on the trim indicator green flag while setting the trim forward on thestick control to lock in the new setting Thermal trim setting seems to be optimized at +8 and LI can be used if the thermal is powerful Speeds slower than 50 kts when in a thermal will not result in an optimum climb rate At high gross weights 55-60kts provides a good measure of aileron control and a better climb rate The DG-400 will climb very well in light lift at the +4 setting especially in the 17- meter mode With 15- meter tips light lift climb performance is less than optimum In fact the aircraft seems to be at its best in all fight regimes with the 17- meter tips installed

Landing with Engine Extended and Stopped To simulate engine failure on takeoff consider at least 500 feet agl as the MINIMUM altitude you would attempt to turn back to the runway for a downwind landing with the engine extended and stopped Deploy full landing flaps to keep your stalling speed as low as possible KEEP THE NOSE DOWN and maintain a minimum indicated airspeed of 55 kts preferably higher Do not flare out high Take the ship right down to the deck for a smooth round out Full stall is not advisable in this condition so a slight main gear first touchdown is preferred to slamming down on 2 points You will not have a lot of time to retract the engine after fai lure on takeoff so it is best to not mess with itYou can use the EMERG retract which will most likely result in damage to engine doors and prop A good rule of thumb is never fiddle with the engine unless your wings are level Never try to start the engine below IOOOagl CEASE ALL START EFFORTS below IOOOagl and concentrate on landing

Landing with Engine Extended and Running The ROTAX is not an enroute cruise engine except to execute a landing with engine out and running Make the downwind leg at partial throttle to indicate about 60 kts and clear the engine at full throttle now and then to keep the plugs from loading up You will find the pattern normal in all respects and need to idle the engine just prior to touchdown Remember that it will take more brake to stop with the engine running at idle

Ground Operations You will find things go better if you select -8 flap immediately after touchdown to maintain lateral control and keep the wings level In the pure sailplane mode retract the spoilers after touchdown to retain rolling energy for the turnoff This is especially tru~ when landing on hard surface fields You must offset the bird on the taxiwaylrunway to keep the wing tip from striking the lights Keep the wingtip wheel on the pavement at all times if operating from a paved strip Taxiing with the canopy open is possible but is not recommended as this can damage the canopy support bracket

6

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Introduction

The information contained herein is a compilation of operational and maintenance procedures and problems gleaned from both personal experience and feed back of data from the Glaser-Dirks factory as well as other DG-400 pilots throughout the world It is by no means comprehensive or complete nor is it meant to replace any procedure found in the factory manual s

From personal experience I have found that owning and tlying a self-launching high performance sa ilplane with a retractable motor to be most rewarding There are definitely two disciplines involved The first of course is the discipline that goes with flying a pure sailplane This includes the search for lift climb and cruise optimization weather factors and the ever present possibility of not finding lift While landing out appears to be so lved by the availability of the motor it becomes quickly evident that the very presence of a retractable powerplant changes the way a soaring pilot conducts each flightThis new discipline has to be learned as you are now a sailplane pilot and a tow pilot The bottom line is there are more decisions to make in the cockpit of a modern selfshylauncher Decisions such as at what altitude above gro und should the engine be extracted when low or what to do if the engine does not start Couple these decisions with the fact that once the engine is extracted soaring performance drops drastically and it becomes very important to get the engine started as quickly as possible Add to this the respons ibility for periodic maintenance of the engine it s retraction system the electrical system the fuel system and propeller and you have quite a bit more to think about and do when you become the pilot of this type of sailplane So you really become two pilo ts and have to shift gears between the two disciplines quic kly and efficiently

Is it worth it I believe it is because with the best of both world s you now have a new found freedom to launch when and where you desire and go where the lift is Yes more time will be spent servicing and maintaining the engine Yes your cruise band will be narrower since the engine must not be extracted at tree top level But once these disciplines are mastered you can enjoy soaring from a vantage point far removed from sail ports tow planes and wing runners Flight safety is no accident and the SLS pilot has to do quite a bit more homework than his purist brother Hopefully this manual will provide some insights into what it is like to fly the DG-400

3

DG-400 SPECI FICA nONS Wing Spans 15M492ft 17M558ft Fuselage Length 229 ft

Wing Areas 1076 ft2 1138 ft2 Aspect Ratios 225 2734 Empty Weights 6746 Ib 6834 Ib Max Weights 1058 Ib 1014 Ib Water Ballast 90 Iiters24 US gal

Max Wing Load 98 Ibft2 891 Ib ft2

PERFORMANCE (STD Conditions Sea Level Hard Surface No Wind Max TOW)

15M 17M VNE (Never Exceed) 146 kts VSI (Stall) 4 I kts 38kts Min Sink 134 fpm48 kts 118 fpm47 kts Max Glide Ratio 42 I 45 I Takeoff Run 754 ft 558 ft Climbing Speed 49 kts Max Climb Rate 600 rpm 700 rpm Distance over 50 Obstacle 1007 ft 886 ft Power Loading 246 Ib hp 236 Ib hp Max G Loads +53 -265 Flap Positions (Degrees) -4-8-10 +4 +6+8+12 (Landing) Approved Maneuvers StallSpinInside LoopChandelle

Lazy EightStall Turn

DG-400 in soaring flight near Minden-Tahoe Airport Minden Nevada USA Photo by Sonja Wenger

4

Flying the DG-400

If you are no stranger to soaring a high performance sailplane then you will be right at home in the cockpit once the engine is stowed Roll rates are crisp in the IS-meter mode and a little slower with the 17- meter tips If you have less than 100 hours in glass ships you should have some instruction in a Janus Twin Astir or Grob 103 Use I 12 spoilers out to simulate engine extended and not running Practice landing approaches this way leaving the spoilers deployed all the way to touch down You will discover your radius of action around the landing field to be close and high

Check Lists Read the handbook and maintenance section and make a series of checklists that cover every aspect of engine operation Do not expect the starter to crank every time you want to start and be ready to dive to over 80 kts to get a windmill start Check your ignition rpm drops carefully No drop on one circuit and engine dies on the other may mean one ignition circuit is defective It is possible for the forward underbelly to touch the ground on a high rpm turnup If this happens EASE the throttle off to keep from banging the tailwheel on the ground with possible damage to the tail wheel steering fork Do not launch unless both ignition circuits check correctly

Taxiing It is a long reach to engine control switches so position yourself accordingly When taxiing you will have to alternate your left hand between the throttle and the spoilerbrake handle Do not taxi too fast About 2 000 rpm seems to be right with 3000+ rpm needed to get moving The flap handle can be used as a brace to hold the spoiler handle back when you need to set the brake while stopped

Takeoff Do not forget to set -4 flaps before applying power and double check the spoilers are LOCKED DOWN Safety pinning the spoiler and aileron connections is a MUST Apply +6 flap for liftoff You can get airborne on-4 flap setting but it takes a lot of up elevator After applying takeoff power rpms should be at least 6000 Watch the airspeed build As it passes 40 kts place flaps in +6 and rotate the aircraft as the airspeed needle hits 49 kts There may be a tendency to exceed 49 kts Adjust trim Watch the tach and keep it below 6200 rpms with attitude correction on the stick If your airspeed fails you can climb right at 49 kts by adjusting the pitch of the aircraft to maintain 6000 rpm on the tach

5

Flap and Trim Settings At speeds above 80 kts quite a bit of forward trim will be required making necessary assisting the trim system by applying forward pressure with your ringer on the trim indicator green flag while setting the trim forward on thestick control to lock in the new setting Thermal trim setting seems to be optimized at +8 and LI can be used if the thermal is powerful Speeds slower than 50 kts when in a thermal will not result in an optimum climb rate At high gross weights 55-60kts provides a good measure of aileron control and a better climb rate The DG-400 will climb very well in light lift at the +4 setting especially in the 17- meter mode With 15- meter tips light lift climb performance is less than optimum In fact the aircraft seems to be at its best in all fight regimes with the 17- meter tips installed

Landing with Engine Extended and Stopped To simulate engine failure on takeoff consider at least 500 feet agl as the MINIMUM altitude you would attempt to turn back to the runway for a downwind landing with the engine extended and stopped Deploy full landing flaps to keep your stalling speed as low as possible KEEP THE NOSE DOWN and maintain a minimum indicated airspeed of 55 kts preferably higher Do not flare out high Take the ship right down to the deck for a smooth round out Full stall is not advisable in this condition so a slight main gear first touchdown is preferred to slamming down on 2 points You will not have a lot of time to retract the engine after fai lure on takeoff so it is best to not mess with itYou can use the EMERG retract which will most likely result in damage to engine doors and prop A good rule of thumb is never fiddle with the engine unless your wings are level Never try to start the engine below IOOOagl CEASE ALL START EFFORTS below IOOOagl and concentrate on landing

Landing with Engine Extended and Running The ROTAX is not an enroute cruise engine except to execute a landing with engine out and running Make the downwind leg at partial throttle to indicate about 60 kts and clear the engine at full throttle now and then to keep the plugs from loading up You will find the pattern normal in all respects and need to idle the engine just prior to touchdown Remember that it will take more brake to stop with the engine running at idle

Ground Operations You will find things go better if you select -8 flap immediately after touchdown to maintain lateral control and keep the wings level In the pure sailplane mode retract the spoilers after touchdown to retain rolling energy for the turnoff This is especially tru~ when landing on hard surface fields You must offset the bird on the taxiwaylrunway to keep the wing tip from striking the lights Keep the wingtip wheel on the pavement at all times if operating from a paved strip Taxiing with the canopy open is possible but is not recommended as this can damage the canopy support bracket

6

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

DG-400 SPECI FICA nONS Wing Spans 15M492ft 17M558ft Fuselage Length 229 ft

Wing Areas 1076 ft2 1138 ft2 Aspect Ratios 225 2734 Empty Weights 6746 Ib 6834 Ib Max Weights 1058 Ib 1014 Ib Water Ballast 90 Iiters24 US gal

Max Wing Load 98 Ibft2 891 Ib ft2

PERFORMANCE (STD Conditions Sea Level Hard Surface No Wind Max TOW)

15M 17M VNE (Never Exceed) 146 kts VSI (Stall) 4 I kts 38kts Min Sink 134 fpm48 kts 118 fpm47 kts Max Glide Ratio 42 I 45 I Takeoff Run 754 ft 558 ft Climbing Speed 49 kts Max Climb Rate 600 rpm 700 rpm Distance over 50 Obstacle 1007 ft 886 ft Power Loading 246 Ib hp 236 Ib hp Max G Loads +53 -265 Flap Positions (Degrees) -4-8-10 +4 +6+8+12 (Landing) Approved Maneuvers StallSpinInside LoopChandelle

Lazy EightStall Turn

DG-400 in soaring flight near Minden-Tahoe Airport Minden Nevada USA Photo by Sonja Wenger

4

Flying the DG-400

If you are no stranger to soaring a high performance sailplane then you will be right at home in the cockpit once the engine is stowed Roll rates are crisp in the IS-meter mode and a little slower with the 17- meter tips If you have less than 100 hours in glass ships you should have some instruction in a Janus Twin Astir or Grob 103 Use I 12 spoilers out to simulate engine extended and not running Practice landing approaches this way leaving the spoilers deployed all the way to touch down You will discover your radius of action around the landing field to be close and high

Check Lists Read the handbook and maintenance section and make a series of checklists that cover every aspect of engine operation Do not expect the starter to crank every time you want to start and be ready to dive to over 80 kts to get a windmill start Check your ignition rpm drops carefully No drop on one circuit and engine dies on the other may mean one ignition circuit is defective It is possible for the forward underbelly to touch the ground on a high rpm turnup If this happens EASE the throttle off to keep from banging the tailwheel on the ground with possible damage to the tail wheel steering fork Do not launch unless both ignition circuits check correctly

Taxiing It is a long reach to engine control switches so position yourself accordingly When taxiing you will have to alternate your left hand between the throttle and the spoilerbrake handle Do not taxi too fast About 2 000 rpm seems to be right with 3000+ rpm needed to get moving The flap handle can be used as a brace to hold the spoiler handle back when you need to set the brake while stopped

Takeoff Do not forget to set -4 flaps before applying power and double check the spoilers are LOCKED DOWN Safety pinning the spoiler and aileron connections is a MUST Apply +6 flap for liftoff You can get airborne on-4 flap setting but it takes a lot of up elevator After applying takeoff power rpms should be at least 6000 Watch the airspeed build As it passes 40 kts place flaps in +6 and rotate the aircraft as the airspeed needle hits 49 kts There may be a tendency to exceed 49 kts Adjust trim Watch the tach and keep it below 6200 rpms with attitude correction on the stick If your airspeed fails you can climb right at 49 kts by adjusting the pitch of the aircraft to maintain 6000 rpm on the tach

5

Flap and Trim Settings At speeds above 80 kts quite a bit of forward trim will be required making necessary assisting the trim system by applying forward pressure with your ringer on the trim indicator green flag while setting the trim forward on thestick control to lock in the new setting Thermal trim setting seems to be optimized at +8 and LI can be used if the thermal is powerful Speeds slower than 50 kts when in a thermal will not result in an optimum climb rate At high gross weights 55-60kts provides a good measure of aileron control and a better climb rate The DG-400 will climb very well in light lift at the +4 setting especially in the 17- meter mode With 15- meter tips light lift climb performance is less than optimum In fact the aircraft seems to be at its best in all fight regimes with the 17- meter tips installed

Landing with Engine Extended and Stopped To simulate engine failure on takeoff consider at least 500 feet agl as the MINIMUM altitude you would attempt to turn back to the runway for a downwind landing with the engine extended and stopped Deploy full landing flaps to keep your stalling speed as low as possible KEEP THE NOSE DOWN and maintain a minimum indicated airspeed of 55 kts preferably higher Do not flare out high Take the ship right down to the deck for a smooth round out Full stall is not advisable in this condition so a slight main gear first touchdown is preferred to slamming down on 2 points You will not have a lot of time to retract the engine after fai lure on takeoff so it is best to not mess with itYou can use the EMERG retract which will most likely result in damage to engine doors and prop A good rule of thumb is never fiddle with the engine unless your wings are level Never try to start the engine below IOOOagl CEASE ALL START EFFORTS below IOOOagl and concentrate on landing

Landing with Engine Extended and Running The ROTAX is not an enroute cruise engine except to execute a landing with engine out and running Make the downwind leg at partial throttle to indicate about 60 kts and clear the engine at full throttle now and then to keep the plugs from loading up You will find the pattern normal in all respects and need to idle the engine just prior to touchdown Remember that it will take more brake to stop with the engine running at idle

Ground Operations You will find things go better if you select -8 flap immediately after touchdown to maintain lateral control and keep the wings level In the pure sailplane mode retract the spoilers after touchdown to retain rolling energy for the turnoff This is especially tru~ when landing on hard surface fields You must offset the bird on the taxiwaylrunway to keep the wing tip from striking the lights Keep the wingtip wheel on the pavement at all times if operating from a paved strip Taxiing with the canopy open is possible but is not recommended as this can damage the canopy support bracket

6

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Flying the DG-400

If you are no stranger to soaring a high performance sailplane then you will be right at home in the cockpit once the engine is stowed Roll rates are crisp in the IS-meter mode and a little slower with the 17- meter tips If you have less than 100 hours in glass ships you should have some instruction in a Janus Twin Astir or Grob 103 Use I 12 spoilers out to simulate engine extended and not running Practice landing approaches this way leaving the spoilers deployed all the way to touch down You will discover your radius of action around the landing field to be close and high

Check Lists Read the handbook and maintenance section and make a series of checklists that cover every aspect of engine operation Do not expect the starter to crank every time you want to start and be ready to dive to over 80 kts to get a windmill start Check your ignition rpm drops carefully No drop on one circuit and engine dies on the other may mean one ignition circuit is defective It is possible for the forward underbelly to touch the ground on a high rpm turnup If this happens EASE the throttle off to keep from banging the tailwheel on the ground with possible damage to the tail wheel steering fork Do not launch unless both ignition circuits check correctly

Taxiing It is a long reach to engine control switches so position yourself accordingly When taxiing you will have to alternate your left hand between the throttle and the spoilerbrake handle Do not taxi too fast About 2 000 rpm seems to be right with 3000+ rpm needed to get moving The flap handle can be used as a brace to hold the spoiler handle back when you need to set the brake while stopped

Takeoff Do not forget to set -4 flaps before applying power and double check the spoilers are LOCKED DOWN Safety pinning the spoiler and aileron connections is a MUST Apply +6 flap for liftoff You can get airborne on-4 flap setting but it takes a lot of up elevator After applying takeoff power rpms should be at least 6000 Watch the airspeed build As it passes 40 kts place flaps in +6 and rotate the aircraft as the airspeed needle hits 49 kts There may be a tendency to exceed 49 kts Adjust trim Watch the tach and keep it below 6200 rpms with attitude correction on the stick If your airspeed fails you can climb right at 49 kts by adjusting the pitch of the aircraft to maintain 6000 rpm on the tach

5

Flap and Trim Settings At speeds above 80 kts quite a bit of forward trim will be required making necessary assisting the trim system by applying forward pressure with your ringer on the trim indicator green flag while setting the trim forward on thestick control to lock in the new setting Thermal trim setting seems to be optimized at +8 and LI can be used if the thermal is powerful Speeds slower than 50 kts when in a thermal will not result in an optimum climb rate At high gross weights 55-60kts provides a good measure of aileron control and a better climb rate The DG-400 will climb very well in light lift at the +4 setting especially in the 17- meter mode With 15- meter tips light lift climb performance is less than optimum In fact the aircraft seems to be at its best in all fight regimes with the 17- meter tips installed

Landing with Engine Extended and Stopped To simulate engine failure on takeoff consider at least 500 feet agl as the MINIMUM altitude you would attempt to turn back to the runway for a downwind landing with the engine extended and stopped Deploy full landing flaps to keep your stalling speed as low as possible KEEP THE NOSE DOWN and maintain a minimum indicated airspeed of 55 kts preferably higher Do not flare out high Take the ship right down to the deck for a smooth round out Full stall is not advisable in this condition so a slight main gear first touchdown is preferred to slamming down on 2 points You will not have a lot of time to retract the engine after fai lure on takeoff so it is best to not mess with itYou can use the EMERG retract which will most likely result in damage to engine doors and prop A good rule of thumb is never fiddle with the engine unless your wings are level Never try to start the engine below IOOOagl CEASE ALL START EFFORTS below IOOOagl and concentrate on landing

Landing with Engine Extended and Running The ROTAX is not an enroute cruise engine except to execute a landing with engine out and running Make the downwind leg at partial throttle to indicate about 60 kts and clear the engine at full throttle now and then to keep the plugs from loading up You will find the pattern normal in all respects and need to idle the engine just prior to touchdown Remember that it will take more brake to stop with the engine running at idle

Ground Operations You will find things go better if you select -8 flap immediately after touchdown to maintain lateral control and keep the wings level In the pure sailplane mode retract the spoilers after touchdown to retain rolling energy for the turnoff This is especially tru~ when landing on hard surface fields You must offset the bird on the taxiwaylrunway to keep the wing tip from striking the lights Keep the wingtip wheel on the pavement at all times if operating from a paved strip Taxiing with the canopy open is possible but is not recommended as this can damage the canopy support bracket

6

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Flap and Trim Settings At speeds above 80 kts quite a bit of forward trim will be required making necessary assisting the trim system by applying forward pressure with your ringer on the trim indicator green flag while setting the trim forward on thestick control to lock in the new setting Thermal trim setting seems to be optimized at +8 and LI can be used if the thermal is powerful Speeds slower than 50 kts when in a thermal will not result in an optimum climb rate At high gross weights 55-60kts provides a good measure of aileron control and a better climb rate The DG-400 will climb very well in light lift at the +4 setting especially in the 17- meter mode With 15- meter tips light lift climb performance is less than optimum In fact the aircraft seems to be at its best in all fight regimes with the 17- meter tips installed

Landing with Engine Extended and Stopped To simulate engine failure on takeoff consider at least 500 feet agl as the MINIMUM altitude you would attempt to turn back to the runway for a downwind landing with the engine extended and stopped Deploy full landing flaps to keep your stalling speed as low as possible KEEP THE NOSE DOWN and maintain a minimum indicated airspeed of 55 kts preferably higher Do not flare out high Take the ship right down to the deck for a smooth round out Full stall is not advisable in this condition so a slight main gear first touchdown is preferred to slamming down on 2 points You will not have a lot of time to retract the engine after fai lure on takeoff so it is best to not mess with itYou can use the EMERG retract which will most likely result in damage to engine doors and prop A good rule of thumb is never fiddle with the engine unless your wings are level Never try to start the engine below IOOOagl CEASE ALL START EFFORTS below IOOOagl and concentrate on landing

Landing with Engine Extended and Running The ROTAX is not an enroute cruise engine except to execute a landing with engine out and running Make the downwind leg at partial throttle to indicate about 60 kts and clear the engine at full throttle now and then to keep the plugs from loading up You will find the pattern normal in all respects and need to idle the engine just prior to touchdown Remember that it will take more brake to stop with the engine running at idle

Ground Operations You will find things go better if you select -8 flap immediately after touchdown to maintain lateral control and keep the wings level In the pure sailplane mode retract the spoilers after touchdown to retain rolling energy for the turnoff This is especially tru~ when landing on hard surface fields You must offset the bird on the taxiwaylrunway to keep the wing tip from striking the lights Keep the wingtip wheel on the pavement at all times if operating from a paved strip Taxiing with the canopy open is possible but is not recommended as this can damage the canopy support bracket

6

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Do not make high power sharp turns on the ground as the tail wheel steering fork will distort and bend Smoothly and easy does it on all taxi operations and try to keep taxi time to a minimum as low engine rpms tend to load the plugs Also make sure your main wheel pressure is at least 43 psi This greatly reduces wear on the main wheel as during taxi loads are on the side of the tread which wears quickly if the tire pressure is low Always clear the engine with at least 5000 rpm after an extended taxi Be careful when doing this as the nose will want to come down even when you hold full brake

If you have a crew the use of a wheel chock is a good idea when checking ignition It is also smart to have a small fire extinguisher handy during all ground starts Provide your crew with ear protectors as the noise level is high during ground runup Many DG-400 pilots will push the aircraft to a spot near the taxiway that leads to the runway prior to starting This reduces engine run time and does away with prolonged taxi operations

Engine and Fuel System Keep your Rotax engine clean Wipe down after each flight This includes the tail boom and rudder-horizontal stab area of the sailplane as spatters will be found after every flight Keep your fuel filters clean and pump from your jerry can thru a filter Check for oil residue in the bottom of the engine bay before and after every flighLThere will be some oil residue as the vacuum fuel pump located near the fuel filler hose weeps thru a small hole This is normal Test engine mount security by pushing on prop blade fore and aft and checking for any slack The Rotax vibrates more at low rpms and smooths out at high rpms Try to stay clear of the vibration rpms

Mix fuel 50 I with a good 2-stroke oil specified for use in an air cooled engine Keep your fuel system as clean as possible Flush fuel tank at least once each season and ALWAYS take a fuel sample prior to each flight Use LL100 aviation fuel or non-leaded 93 octane auto fuels withNO ALCOHOL additives

Electrical System Do not depend on the generator to recharge your batteries completely as the engine is on but a short period Check your battery level in flight and remember the battery must have enough power to raise the engine and swing the blades at about 300 rpm for a successful start The batteries do not provide spark to the plugs This is accomplished with the CDI system located behind the flywheel If the ignition system does not check out the problem can be either in the electronic boxes (2) located just under the flywheel or in the magneto system (coils) located behind the flywheel A licensed mechanic should remove the flywheel You should have the Rotax Service and Parts manuals for reference plus the Tillotson Carbo Parts List These are available from Rotax the DG dealer and ASA Publications

7

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Engine Inspections The 25 hour engine inspections are important and should be carried out by a qualified mechanic or at least signed off by a mechanic after completion by the pilot This is not a complex inspection and should be done once a year as it takes a long time to reach 25 hours of engine time See the Maintenance Section of the Flight Manual

Cautions I Engine Mounting Bolts These have failed in the past but the latest TNs solve the problem Look carefully at all engine mount bolt heads to see if marker paint is disturbed Vibration is the cause

2 Propeller Drive Belt Keep this taut as per handbook Discover how to tighten by reading the manual A loose or sloppy drive belt wreaks havoc on the engine mounting system

3 Propeller Mounting Bolts Check torque values If aircraft is moved to drier climate prop bolls can loosen due to wood shrinkage

4Ignition Boxes The old Polar Fire Bosch boxes are no longer available A change to the Ducati boxes is necessary if a Polar Fire box fails Contact DG for Ducati Boxes and the mounting hardware kit

5 Carb Idle Adjust needles evenly Uneven adjustments can result in too lean a mixture thereby creating a hot running engine and resultant failure due to inadequate lubrication Beller to be rich than lean

6 Starter Failure If starter does not operate check the spade connectors at forward left side of engine The engine tower support must be removed to remove the starter A local starter shop can repair the starter Keep a spare starter

7 CHT Probe Exits at top of 2 cylinder head Screws in If this comes loose compression is lost Shut down retract and land if a loud flapping noise is heard

8 Propeller Brake Prop hits engineprop bay doors upon extension or retraction Cause Prop not centered or moves off center ~Center prop check lite out on DEI and continue to firmly hold prop brake on until full retraction or extension is accomplished Assure flywheel surface where prop brake strikes is clear of oil Adjust prop brake cable

8

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Solving Hard to Start Problems

I Low battery resulting in not enough cranking power 300rpm is necessary for the CDI system to produce a hot spark

2 Improper use of choke and or throttle during start This problem can be solved by setting jus t a hair of open throttle and full choke (cold engine) After about 10 blades the engine should start DO NOT touch the throttle as this varies the fuelair mixture As the engine starts slowly push the choke in to the off position to keep the engine running smoothly If it hesitates stop pushing the choke in and continue on in as the engine begins to run stronger If you are making an air start and the engine acts a little balky increase airspeed to aid cranking You can also ma ke a nice air start by windmilling the prop with slipstream at 75-90 kts providing the ignition switch is on

3 If you fly from fields over 4000 msl install high-altitude jets to keep the mixture from being too rich DO NOT fiddle too much with the idle needle val ves They should always be set at identical setting Lets face it this engine is not a real smooth idler below 3000 rpms So try to stay between2700 and 3000 for low vibration and have someone look at the prop drive belt at various rpms to see when it bows out Check your tach and try to stay clear of these rpms

4 Also check your fuel filters they maybe partially blocked resulting in reduced fuel flow Make sure your prop drive belt is taut and within spec of handbook

5 Experience has shown that once the Rotax 505 is getting the fuel it needs to run full power at 6000+ rpms it takes a mortar shot to stop it

6 It has also been discovered that the plugs should be changed after 15 hours engine run time or 50 starts whichever occurs first When starting becomes difficult just change the plugs as they are upside down and are subject to fuel fouling all of the time A change of plugs every season is a good investment

9

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

DG-400 Fluids Capacities amp Operational Capabilities

Fluids Oil =Yamahil Yamillube R - Mix 1 pI t(lS galkms gas Gas = Min 96 ocr ROZ or A VGAS 1 (X)LL ()r mix 12 ilnd 12 PluhS =NGKO ES130SCH W 25012 or I30SCH W4C

Capacities amp Weights Fuse fuel tank 20L = S3 US gallons = 318 Wing fuel tanks =lSL ea (4gillwing) =JOL =RUS gill =475 Water ballast =90 liters =23R US gal (118wing) == 1985

Battery System rllllr bV-WAH wired seriesparillllI =12V-20AH

Ballast No ballast-lift Jkts and under 11 gilllons-lift 4-6 kts 238 gall(lns - lift 6 kls and lip

Fuel Consumption 20LlHR (5 galhr) at 62Xl RPM

Filling Fuel Tanks Fuse-Pump in wiU hose using pumpfilter system plugged into power supply socket left-reM baggage compartment or extemal12V battery

Nillg- Use suction side of pump to draw air out 1 minute then reverse and fill Recunnect to fuselilge tank

Takeoff Distances Gross Weights ALTMSL TEMPF ISM lOS8 17M 1014

Sea level 32 719 S32 amp) 797 SR7

1640 32 7S4 5SR 86 84J 623

4920 32 856 633 86 951 702

2Sdeg less with Skt headwind - 35 more with Skt tailwind

10

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Flap PositionslWing Loadings

LOSSOFT 81 22 FJapO loS7 lAS to 60 lAS

-4 loMIAS lo86IAS -8 lo92 lAS lo97lAS

-10 92+ lAS 97+ lAS

Engine Limitations 6800RPM 1 MIN MAX CHT MAX-25OC 6200 CLIMB RPM MAX

Performance 1ZM 15M Fuel+wt 5L Gross 5L Gross WingLd 85 89 89 98 LDlaquo-4F) 44 45 41 42 lAS (kts) 60 64 62 --66 MS (OFLAP) 44 47 44 --47

Rotax 505 Engine installation in a DG-400 Williams 11

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

DG 400 Check Lists

Pre-fliglll Visual Checks AileronSpeed Drake Safetied All controls-Pos Check Horiz Stab LockedSafetied Tires Up Water Dallast Secure Wing Tips Safetied Wing Tanks Connected TE Probes Secure Statics Clear

Ellgille Bay Illspectiol Engine Extend Retract-13 sec Fuel Drain Checked ThrotiChoke Pos Check Drive Belt Tension Fuel Tank Full Engine Bay Fuel Cock-On Prop Inspection Exhaust Manifold

Cockpit Checks Strap In02 Check Tail Dolly Off Ignition-Off Elev Trim Slight Down Speed Brakes Cycle+Lock Altimeter Set Fuel Cock-On Wing Fuel Tanks Off -4 FlapGear Locked Down

Masler Swilclr-On DEI-AVIONK+EngineStatic-Up DEI-Read FueIQ+Batt+Cht+Red Lite Set Tank QUantity at21L Radio and Varios-On Set Computer Extend Engine-Check Door Lite Out

Starlillg Engine Ignition Switch-On -Green DEI Lite-On Set Choke (Pullput Full for Cold Eng) Set Throttle (1 2) Prop Clear

12

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Hit Starter Button Push Choke In and Add Throttle Engine Runs-Close Canopy 3000 RPM-Check Mags (300MAX Drop) 5800 RPM-(Helper at Nose) Select Avionik (RPM Drops-Check Fuel Filter) Select Avionik+Engine 2700 RPM-DEI=FueIQ+RPM+Cht+Green Lite

Start Trouble SllOotitlg No Start 10 Sec=F100ding Choke Off=Full Throttle Hit Button As Engine runs-reduce throttle No Start after 2nd try-Resume normal start procedures

Ready For Takpoundojf-Check Speed Bmkes Locked

Takeojf -4 FlapsTrim slight nose down Increase throttle fully6ltXXJ+RPM Lift wing as Ailerons become effective +6 Flaps (or liftoff (GrassSoft Field use Ll)

X-WitldTakeojf Full back stick (wing down windward) -10 Flap When rudder effective +6 Flap

C1imbout Maintain full throttle 6HXgt=MAXCONT6200=5Min68OO=MAX 49 KlAS or to 43KIAS to reduce RPM Gear up at 1000l5O CHT MAX

Slopping atld Retracting Ellgine Adjust Mirror Throttle-IdIe Check Cl-IT 180 or under Ignition-Off 49 KlAS-F1aps 0 Apply Prop Brake Retract Switch to Left-When Prop vertical and Prop warning lite out [to windmill inc speed to 54-59 KIAS]

13

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Hold prop brake on until retraction romplete and door lite out Switch to Avoinik-Down I TESwitch down Check all DEI Switches-Down

Ellgine Extension and Air Start Engine out and not running = 131 LID at 49KlAS 4 KTSMIN Descent=Landing in

3 min from 1500 AGL 36 SM 4 min from 2000 AGL 49 SM 5 min from 2500 AGL 61 SM 6 min from 3000 AGL 73 SM (All above with no wind)

Airstart 49 KlASFlaps+6 Master Switch-0n DEI to Avionik + Engine Engine Ext Switch-Right Engine Door Lite-Out Pull Out Full Choke=Cold Pull Out 12 Choke=Warm Thro ttle= 1 12 to 34 IhTIition Switch-On DEI Green Control Lite-On Hit Start Button Engine Starts-Add Throttle Push Choke-In Full Throttle

Fast Method IhTIition On Start button pressed during extension

Engine will begin cranking just before full extension

Make sure door lite is out

49 KIAS Climb

Air Start Without Starter (WindmilJ Start) Choke Out Halfway Push over to attain 90+ K1S Throttle 12 2 G Pullout as engine startsChoke-0ff Ignition-0n 500 Altitude Loss (Engine usually starts on third revolution of prop)

Emergency Procedwes

Power Loss on Takeoff-Select L1 and Land Off Field-Fuel Off Main Switch-Off Ignition-Off

Keep Flying Speed and Pray Engille Fire

bull On gOlUld-Master Ignition switch -OffIFuel-Off bull In air- Master Ignition switch-OfflFuel-OfflOpen Throttle bull Close chokelLand with engfne extended

14

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Flight Configurations DG-400

Wing Ar~i1 LSl2an 1Q76Ll~M 11J807M Mode Config LD GW WL LD GW WL 2 Pilot 415 944 877 44 952 836

oFuell3al

44 985 856 Fuel

JF Pilot+20L 415 977 907

30 Pilot +H20 42 ]058 98 45 1014 89

(01 only) (1366Gal) (74Gal)

3F13 Pilot+20L 42 1058 98 45 1014 89 Fuel+H20 (97Gal) (35Gill)

4FF Pilot+50L 42 1027 954 45 1014 89 41 LTR=MAX 11 Gal3 per wing

513 Pilot+ Engine 42 1058 98 45 1014 89 removed + (255Gal) (193Gal) MAX H20

LD=Polar GW=Gross Weight WL=Wing Loading (2amp5 no fuel) F=Fuel l3=Oallast FF=Full fuel including wing tanks

Sawtooth Cruise1500 to 6500 Agi Climb and Glide 76KIAS to 15M 525 Gal Fuse Fuel =204NM (235SM) 65KTS (749MPH) 3+08 ETE 792 Gal Wing Fuel =309NM (355SM) 65KTS (749MPH) 4+50 ETE 1317Gal Full Fuel =S13NM(S9ffiM) 65KTS(749MPH)7+S8ETE Fuel ComsumptiOll 39NMIGal 1ONM Liter TypCycle30Min=36NM=36 Liter

15

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Suggested 10 Hight Orientation in the DG-400

The purpose of these flights is to become completely familiar with the various modes of operating and flying the DG-400lntensestudyofthe pilots operating manual is necessary prior to behgtinning these flights Use full fuselage fuel Except for towed flights all powered takeoffs without wing runner

Flt and Activity

1 Normal tow in 15M mode Slow flight stalls minimum sink At best LID cycle to all flap pOSitions with final position L1 and spoilers full out Land

C1b Time

Fuel Used

Air St

All Loss

CHT Max

2 Normal tow in 17M mode Complete all Flight 1 checks Land

3 Review engine failureon T I OSeIf-launch in 15M mode Climb to 5M agl and stow engine Land with engine stowed

4 Self-launch in 17M mode Complete all Right3 checks Land with engine stowed

5 Self-launch in 15M modeand climb to5M agl and stow engine At 4M extend enshygine and restart Climb to 5M Agl and stow engine Land with engine stowed

6 Self-launch in 17M mode Complete all RightS checks Land with engine stowed

7 Self-launch in 15M mode Climb to 5M ag and stow engine Extend and restart engine at 25M agl Land with engine running and taxi in

8 Self-launch in 17M mode and repeat Flight 7

9 Self-launch in 15M mode C1imbto5Magl and stow engine At 25M extend engine and land with engine extended and off

10 Self-launch in 17M mode Repeat Flight 9

16

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Goals to Attain

o 1 A smooth and repeatable pre-flight check list

o 2 A dependable initial start sequence Use of the throttle and choke are critical upon initial start

o 3 Can all DEI switches be easily reached Are all DEI lights working properly Can you pass a blind-fold check on the name and position ofall DEI indicators and switches

o 4 Are elevator trim and wing flap positions providing the measure of pitch and roll response you need to lift the wing on take-off roll and rotate for lift-off

o 5 Are Ue engine RPMs kept within limits during roll lift-off and climb

o 6 Haveyou discovered the rough RPM areas where vibration is excessive

o 7 Have you mastered the prop brake to position the prop properly for retraction Desureand keep the prop brakeon until retraction is complete Also remember at airspeeds of over 49 KJAS the prop will tend to windmill upon extension of the engine Again use the prop brake when extend ing to preclude engine door and prop damage

D 8 Have you discovered Ue proper amount of choke when air starting a warm vs a cold engine

o 9 Are you staying close aboard the departure field on takeoff and mentally simulating a malfunctioning or dead engine after takeoff

o 10 Have you practiced the recommended cross-wind takeoff routine

o 11 How much fuel is consumed on a normal launch

o 12 AIe you prepared for an engine fire during ground start Air start

o 13 Have you practiced extending or retracting the engine using the Emershygency System

o 14 Have you listed the steps for baH out

o 15 Have you planned and flown a saw-tooth ferry flight

o 16 Do you check fuel filters and cocks before each flight including draining a fuel sample from the sump

o 17 Are both the throttle and choke linkages checked free and operable before each flight

o 18 Do you time the engine extension cycle prior to each flight

17

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Annual Inspection for Glaser-Dirks Sailplane DG-400 Per Maintenance Manual Updated April 1988

Page 26 Issued Feb 1987 Section 222

Annual Inspection date __________________

lnspected by _____________________

Aircraft ModeISerialDG-400 ______________

LnstAnnualdate ____________________

Last 25 hr engine check DateEngine hrs

Current Airframe hours ____ Current engine hours ______

Aircraft weighed and CG recomputed date ___________

Checked Logbook for AD and T N currency __________

IIspectioll 1 Check rudder cables for wearespecia IIy around S tubeson the rudder pedals

Worn cables should be replaced See Section 4Y (Maint Manual)

2 All control circuits Inspect all bolted connections and locking devices ie locknuts split pins etc

Check all control circuits for adequate greasing and rust prevenshytion (Section 33) Aileron connections Airbrake connections Push rod guides on left side cockpit All control rod bearings at Fuse access hatch and under control stick in cockpit Rudder pedal adjustment guide All hinge points on undercarriage AU control surface hinges Ball seats on Hotellier quick connects Elevator control hooku p Pinsand bushing on elevator and wing attachment points Remove canopy and grease lockingmedl Oean andgrease powerplant extension mech

3 Check Tow Hook for cleanliness and releaselube

4 Propeller Remove and inspect for cracks at hub boss Reinstall and torque bolts to 11 ft Ibs Safety wire with max 8 rotationsinch Mark bolt heads positions with safety paint Retorque and resafety after first flight

18

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

5 Assure aircraft weighed and CG computed at least every 4 years or after significant change in weight or any work or equipment additions that can influence the CG

Aircraft inspected and found airworthy

Notes

19

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Weight and Balance

DG-400Serial No_________ Registration No_______

WeighillgColifiguratioll Enhgtine Retracted No fuel Water Ballast tanks eTlpty Datum Wing leading edge at root rib Leveling line 100367 on tail boom Accessories and instruments per equipment list

Empty weight procedure 1 Glider assembled with gear down 2 Fuse level per 100367 slope 3 Ascertain wings are level 4 Record Gross Empty Weight in both 1517 meter confihUralions 5 Record Empty Weight at tail wheel in both 1517 meter

configurations

F1igllt Weight Procedure lSame as 1-3 above 2 Pilot parachute equipment in cockpit 3 Record Gross Flight Weight in both 1517 meter configurations 4 Record Right Weight at tailwheel in both 1517 meter

configurations

eG Formulas

Given a=13mm (distance MLG axle is ahead of datum) b=435Omm (distance from datum to axle of tailwheel)

~ 15 1Z GE=GrossEmptyWeight _______+-__ kglb W2E=Tailwheel Weight Empty kglb GF=Gross Flight Weight kglb W2F=Tailwheel WeightFlight kglb

Empty Weight CG 15 meter= W2E Xb +a =_______mm (use kg and mm) GE

17 meter= W2E X b +a =_______mm GE

Approved Empty Weight CG Range ___mm to ______mm

20

Flight Weight CG] 5 meter= W2F X b + a = _______mm (use kgand mm) GE

17 meter= W2F Xb + a = _______mm GE

bullbull Approved In-Right Weight CG Range 2SOmm to 39Omm

Diagram ] 0 April 1988 DG-400 Maintenance M1nual bullbull Section 28 page 20 DG-400 Flight Manual Note All measurements obtained from Factory Weighting Record of ____

Date

lhis aircraft weighed and Weight and Balance Computed on _______ Authorized Signature Title and Certification Number

Flight Manu1 Revised thru __-=----__byTN __________ (Date)

Soaring Math

1 NM 1150777 SM 1000 km =62138818 SM = 53997265 NM

] SM = 868978 N M 750 km = 46604113 SM 40497948 NM 500 km 31069409 SM 26998632 NM

1 KM = 621388 SM 300 km =18641645SM =16199179 NM 100 km = 62138818 SM = 53997265 NM

] GAL 1280Z

H20 83451bsGAL

1 GAL = 37854 LITERS

1 inch = 254mm

1 Kg = 22046 Ibs

1 Ib 453( Kg

1 ft = 3048 meter

1 meter 328 ft

00deg00 00 0021

DEI Display 4 6 5 7 8

1 Throttle amp Starter Button bull Starter Dutton is live when Ignition Switch is ON amp Engine is Extended amp not running

2 Ignition Switch (Up = On) bull Retrltlction Circuit Isolltlted bull Stltlrter Circuit ON bull Electric Fuel Pump On

3 Propeller Door Warning Light bull OFF-Doors Closed bull Flashing YELLOW-Door Open or not Totltly Closed

4 Fuselage Fuel Tank Quantity (Liters) bull Must be re5et when tank fueled

5 Fuel Quantity Reset bull Push to reset or tum screw after each filling

6 CHTBaltery Display Switch bull LEFf=CHTCelsius bull RIGHT =Dattery Volts Battery gt 147SV or lt 110V + Display Blinks

7 Propeller Position Warning Light bull If Dlinking RED Prop not vertical amp Engine Retraction Stops bull Must Re-Extend Engine amp ReshyPosition Prop amp Attempt another Retraction Cycle bull NO LIGHT =Prop in correct position

9 11 10

8 Avionik + EngineAvionik Power Switch bull UP=lower to Avioniks + Engine for Starting and running Engine bull DOWN=Power for Avioniks Instruments only = For Solring Flight

9 StaticslTE Switch bull UP= Varios Operate on Static Pressure=U5e when Engine is Runningmiddot DOWN=Varios Operate on TE System=Use for 5ltlltlring Flight

10 Generator Light bull ON (RED)=Generator not charging batteries bull OFF=Generltltorcharging batteries

11 Engine RPMs bull Digital Display First 3 Numerals 61 2 = 6120 rpms bull Colon () Dlinks when over 6100 (Max Continuous) bull Total Display Dlinks when atover 6800 rpms

12 Start Warning Light bull GREEN=Circuit is free Engine can be stltlrted bull OFF=Engine not fully extended bull Ignition Switch OFF bull Engine is running

13 Ignition Test Switch bull Switch centered=l3oth Ignition Circuits Activated bull LEFT = Test Circuit I middotIZlGHT =Test Circuit II bull Mx RPM Drop 300 during test

22

Suggested Spare Parts Kit for DG-400

Part No Description

60507572 Fuel Filters (3) 60500131 Starter Motor (Order parts 4M51 amp 4M52 amp

4M70 installation hardware) 60504011 Drive Belt HDT 12oo-8M-5O 60000175 Gas Spring for extensionretraction drive

AiL 0-02-2500N 60507560 12V Electric Fuel Pump (Facet 40105) 39001000 Fuel Line set for Tillotson Carbs 39001001 Fuel Line set for Mikuni Carbs 60507650 Fuel Cock (Gotz 755008) 50575260 Regulator Voltage4E26 60510350 ExtRet Relay 073300 60510812 Starter Relay 0332002160

Key for main switch 0341001001 60510420 Fuse Set (6) 60500115 Muffler Springs (4) 40470350 Brake pad for propeller brake 4 M 35 40460250 Tail Wheel Steering Fork 4 R 25 60500230 High Altitude Main jets (2)045 962 962 60510461 Limi t Swi tch Engine extended 164-135 60510462 Limit Switch Engine retracted 164-594 60510550 Proximity Switch lnsor INCT 1202

23

For more information about the DG-400 contact the following

Airframe Manufacturer

DG Flugzeugbau GMBH Postfach 4120 0-7520 Bruchsal4 GERMANY Attn Wilhelm Dirks Dip -Ing Tel 011-49-7257-8911 Telefax 011-49-7257-8922

Rotax Engine Factory

Bombardier-Rotax GMBH Motorenfabrik A-4623 Gunskirchen AUSTRIA Tel 011-43-7246-2710 Telefax 01 143-724amp271286

US DistributorDealer

Oliver Dyer-Bennet Glaser-Dirks USA 5847 Sharpe Rd Calistoga CA 94515 USA Tel 707-942-5727 FAX 707-942-0885

For information about the Auxiliary-powered Sailplane Association Inc contact

SSA POBox 2100 Hobbs NM 88241-2100 Pho505-392- 1177 Em ail infossaorg Internet httpssaorg

DEI Display 4 6 5 7 8

1 Throttle amp Starter Button bull Starter Dutton is live when Ignition Switch is ON amp Engine is Extended amp not running

2 Ignition Switch (Up = On) bull Retrltlction Circuit Isolltlted bull Stltlrter Circuit ON bull Electric Fuel Pump On

3 Propeller Door Warning Light bull OFF-Doors Closed bull Flashing YELLOW-Door Open or not Totltly Closed

4 Fuselage Fuel Tank Quantity (Liters) bull Must be re5et when tank fueled

5 Fuel Quantity Reset bull Push to reset or tum screw after each filling

6 CHTBaltery Display Switch bull LEFf=CHTCelsius bull RIGHT =Dattery Volts Battery gt 147SV or lt 110V + Display Blinks

7 Propeller Position Warning Light bull If Dlinking RED Prop not vertical amp Engine Retraction Stops bull Must Re-Extend Engine amp ReshyPosition Prop amp Attempt another Retraction Cycle bull NO LIGHT =Prop in correct position

9 11 10

8 Avionik + EngineAvionik Power Switch bull UP=lower to Avioniks + Engine for Starting and running Engine bull DOWN=Power for Avioniks Instruments only = For Solring Flight

9 StaticslTE Switch bull UP= Varios Operate on Static Pressure=U5e when Engine is Runningmiddot DOWN=Varios Operate on TE System=Use for 5ltlltlring Flight

10 Generator Light bull ON (RED)=Generator not charging batteries bull OFF=Generltltorcharging batteries

11 Engine RPMs bull Digital Display First 3 Numerals 61 2 = 6120 rpms bull Colon () Dlinks when over 6100 (Max Continuous) bull Total Display Dlinks when atover 6800 rpms

12 Start Warning Light bull GREEN=Circuit is free Engine can be stltlrted bull OFF=Engine not fully extended bull Ignition Switch OFF bull Engine is running

13 Ignition Test Switch bull Switch centered=l3oth Ignition Circuits Activated bull LEFT = Test Circuit I middotIZlGHT =Test Circuit II bull Mx RPM Drop 300 during test

22

Suggested Spare Parts Kit for DG-400

Part No Description

60507572 Fuel Filters (3) 60500131 Starter Motor (Order parts 4M51 amp 4M52 amp

4M70 installation hardware) 60504011 Drive Belt HDT 12oo-8M-5O 60000175 Gas Spring for extensionretraction drive

AiL 0-02-2500N 60507560 12V Electric Fuel Pump (Facet 40105) 39001000 Fuel Line set for Tillotson Carbs 39001001 Fuel Line set for Mikuni Carbs 60507650 Fuel Cock (Gotz 755008) 50575260 Regulator Voltage4E26 60510350 ExtRet Relay 073300 60510812 Starter Relay 0332002160

Key for main switch 0341001001 60510420 Fuse Set (6) 60500115 Muffler Springs (4) 40470350 Brake pad for propeller brake 4 M 35 40460250 Tail Wheel Steering Fork 4 R 25 60500230 High Altitude Main jets (2)045 962 962 60510461 Limi t Swi tch Engine extended 164-135 60510462 Limit Switch Engine retracted 164-594 60510550 Proximity Switch lnsor INCT 1202

23

For more information about the DG-400 contact the following

Airframe Manufacturer

DG Flugzeugbau GMBH Postfach 4120 0-7520 Bruchsal4 GERMANY Attn Wilhelm Dirks Dip -Ing Tel 011-49-7257-8911 Telefax 011-49-7257-8922

Rotax Engine Factory

Bombardier-Rotax GMBH Motorenfabrik A-4623 Gunskirchen AUSTRIA Tel 011-43-7246-2710 Telefax 01 143-724amp271286

US DistributorDealer

Oliver Dyer-Bennet Glaser-Dirks USA 5847 Sharpe Rd Calistoga CA 94515 USA Tel 707-942-5727 FAX 707-942-0885

For information about the Auxiliary-powered Sailplane Association Inc contact

SSA POBox 2100 Hobbs NM 88241-2100 Pho505-392- 1177 Em ail infossaorg Internet httpssaorg

Suggested Spare Parts Kit for DG-400

Part No Description

60507572 Fuel Filters (3) 60500131 Starter Motor (Order parts 4M51 amp 4M52 amp

4M70 installation hardware) 60504011 Drive Belt HDT 12oo-8M-5O 60000175 Gas Spring for extensionretraction drive

AiL 0-02-2500N 60507560 12V Electric Fuel Pump (Facet 40105) 39001000 Fuel Line set for Tillotson Carbs 39001001 Fuel Line set for Mikuni Carbs 60507650 Fuel Cock (Gotz 755008) 50575260 Regulator Voltage4E26 60510350 ExtRet Relay 073300 60510812 Starter Relay 0332002160

Key for main switch 0341001001 60510420 Fuse Set (6) 60500115 Muffler Springs (4) 40470350 Brake pad for propeller brake 4 M 35 40460250 Tail Wheel Steering Fork 4 R 25 60500230 High Altitude Main jets (2)045 962 962 60510461 Limi t Swi tch Engine extended 164-135 60510462 Limit Switch Engine retracted 164-594 60510550 Proximity Switch lnsor INCT 1202

23

For more information about the DG-400 contact the following

Airframe Manufacturer

DG Flugzeugbau GMBH Postfach 4120 0-7520 Bruchsal4 GERMANY Attn Wilhelm Dirks Dip -Ing Tel 011-49-7257-8911 Telefax 011-49-7257-8922

Rotax Engine Factory

Bombardier-Rotax GMBH Motorenfabrik A-4623 Gunskirchen AUSTRIA Tel 011-43-7246-2710 Telefax 01 143-724amp271286

US DistributorDealer

Oliver Dyer-Bennet Glaser-Dirks USA 5847 Sharpe Rd Calistoga CA 94515 USA Tel 707-942-5727 FAX 707-942-0885

For information about the Auxiliary-powered Sailplane Association Inc contact

SSA POBox 2100 Hobbs NM 88241-2100 Pho505-392- 1177 Em ail infossaorg Internet httpssaorg

For more information about the DG-400 contact the following

Airframe Manufacturer

DG Flugzeugbau GMBH Postfach 4120 0-7520 Bruchsal4 GERMANY Attn Wilhelm Dirks Dip -Ing Tel 011-49-7257-8911 Telefax 011-49-7257-8922

Rotax Engine Factory

Bombardier-Rotax GMBH Motorenfabrik A-4623 Gunskirchen AUSTRIA Tel 011-43-7246-2710 Telefax 01 143-724amp271286

US DistributorDealer

Oliver Dyer-Bennet Glaser-Dirks USA 5847 Sharpe Rd Calistoga CA 94515 USA Tel 707-942-5727 FAX 707-942-0885

For information about the Auxiliary-powered Sailplane Association Inc contact

SSA POBox 2100 Hobbs NM 88241-2100 Pho505-392- 1177 Em ail infossaorg Internet httpssaorg