Allstar PZL Glider SZD-54-2 Perkoz Operating manual

Doc No. 542.4.02
Issue II April 2014
corrected
Allstar PZL Glider
Sp. z o.o.
TECHNICAL SERVICE
MANUAL
for a sailplane
Model: SZD-54-2 „Perkoz”
Serial No.:
Registration:
TRANSLATION OF THIS DOCUMENT AND CONVERSION OF TECHNICAL DATA HAVE BEEN
DONE BY BEST KNOWLEDGE AND JUDGMENT
IN ANY CASE OF DISCREPANCIES IN TRANSLATION THE POLISH VERSION SHOULD BE USED
THIS MANUAL IS TO BE ALWAYS AVAILABLE DURING ROUTINE MAINTENANCE OPERATION,
INSPECTION AND PERIODIC WORKS.

corrected
Note to English version, Issue II ‒ April 2014, corrected:
By the way of the Revision No. 2 implementation, the whole Technical Service
Manual in English was checked and corrected in order to eliminate mistakes found
and to be in line with Polish version. The corrections are not indicated to achieve
compatibility with Polish version, however all pages are marked with “corrected” in
the footer to distinguish them from previous not corrected editions. Therefore this
edition of the Technical Service Manual replaces the previous one as a whole.
Intentionally left blank

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision No. 2 May 2017
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.1
corrected
SECTION 0.
ISSUANCES
0.1. Record of revisions
Any revision of the present Manual must be recorded in the following table and
- in case of Sections 10. and 16. - endorsed by the Agency (EASA).
The new or amended text in the revised page will be indicated by a black
vertical line in the outer margin and the Revision No. The number and date of the last
revision will be shown in the footer of the page.
With every revision implementation, the pages affected with this revision and
listed in the following table must be replaced.
Rev.
No.
Affected
Section
Affected Pages
Date of
Issue
No. and Date of Approval
Insertion
Date & Signature
1
0
2
4
16
0.1, 0.4
0.5, 0.12
2.1, 2.2,
2.3, 2.4
4.2
16.8
July
2015
10056004
14.12.2015
Valid for serial number
542.A.15.010 and next as
well as for previous S/N
with a change implemented
acc. to am. Approval
2
0
1
2
3
5
6
7
8
9
11
15
16
17
18
0.1, 0.4, 0.5,
0.7, 0.8, 0.12
1.2, 1.3
2.22, 2.26, 2.27
2.31, 2.33, 2.35
2.37, 2.41
3.5
5.2
6.2
7.3, 7.4
7.6 ,7.8
8.1, 8.3, 8.5
8.6, 8.7, 8.8
9.1
11.1
15.1, 15.2,
15.3, 15.4,
16.1, 16.7,
16.9, 16.10
17.4, 17.10,
17.18, 17.20,
17.24, 17.28,
17.30
18.4, 18.10,
18.11, 18.12
May
2017
10062739
10062741
26.07.2017
2

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.2
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision
corrected
Rev.
No.
Affected
Section
Affected Pages
Date of
Issue
No. and Date of Approval
Insertion
Date & Signature

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.3
corrected
Rev.
No.
Affected
Section
Affected Pages
Date of
Issue
No. and Date of Approval
Insertion
Date & Signature

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.4
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision No. 2 May 2017
corrected
0.2. List of effective pages
Section
Page
Date of Issue
Section
Page
Date of Issue
2
0
0.1
May 2017
2
2.25
April 2014
0.2
April 2014
2.26
May 2017
2
0.3
April 2014
2.27
May 2017
2
2
0.4
May 2017
2.28
April 2014
2
0.5
May 2017
2.29
April 2014
0.6
April 2014
2.30
April 2014
2
0.7
May 2017
2.31
May 2017
2
2
0.8
May 2017
2.32
April 2014
0.9
April 2014
2.33
May 2017
2
0.10
April 2014
2.34
April 2014
0.11
April 2014
2.35
May 2017
2
2
0.12
May 2017
2.36
April 2014
0.13
April 2014
2.37
May 2017
2
0.14
April 2014
2.38
April 2014
2.39
April 2014
1
1.1
April 2014
2.40
April 2014
2
1.2
May 2017
2.41
May 2017
2
2
1.3
May 2017
2.42
April 2014
1.4
April 2014
1.5
April 2014
3
3.1
April 2014
1.6
April 2014
3.2
April 2014
3.3
April 2014
1
2
2.1
July 2015
3.4
April 2014
1
2.2
July 2015
3.5
May 2017
2
1
2.3
July 2015
3.6
April 2014
1
2.4
July 2015
2.5
April 2014
4
4.1
April 2014
2.6
April 2014
4.2
July 2015
1
2.7
April 2014
2.8
April 2014
5
5.1
April 2014
2.9
April 2014
5.2
May 2017
2
2.10
April 2014
5.3
April 2014
2.11
April 2014
5.4
April 2014
2.12
April 2014
2.13
April 2014
6
6.1
April 2014
2.14
April 2014
6.2
May 2017
2
2.15
April 2014
2.16
April 2014
7
7.1
April 2014
2.17
April 2014
7.2
April 2014
2.18
April 2014
7.3
May 2017
2
2.19
April 2014
7.4
May 2017
2
2.20
April 2014
7.5
April 2014
2.21
April 2014
7.6
May 2017
2
2
2.22
May 2017
7.7
April 2014
2.23
April 2014
7.8
May 2017
2
2.24
April 2014

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision No. 2 May 2017
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.5
corrected
Section
Page
Date of Issue
Section
Page
Date of Issue
Section
Page
Date of Issue
2
8
8.1
May 2017
17
17.1
April 2014
8.2
April 2014
17.2
April 2014
2
8.3
May 2017
17.3
April 2014
8.4
April 2014
17.4
May 2017
2
2
8.5
May 2017
17.5
April 2014
2
8.6
May 2017
17.6
April 2014
2
8.7
May 2017
17.7
April 2014
2
8.8
May 2017
17.8
April 2014
17.9
April 2014
2
9
9.1
May 2017
17.10
May 2017
2
9.2
April 2014
17.11
April 2014
9.3
April 2014
17.12
April 2014
9.4
April 2014
17.13
April 2014
17.14
April 2014
10
10.1
April 2014
17.15
April 2014
10.2
April 2014
17.16
April 2014
17.17
April 2014
2
11
11.1
May 2017
17.18
May 2017
2
11.2
April 2014
17.19
April 2014
17.20
May 2017
2
12
12.1
April 2014
17.21
April 2014
12.2
April 2014
17.22
April 2014
17.23
April 2014
13
13.1
April 2014
17.24
May 2017
2
13.2
April 2014
17.25
April 2014
13.3
April 2014
17.26
April 2014
13.4
April 2014
17.27
April 2014
17.28
May 2017
2
14
14.1
April 2014
17.29
April 2014
14.2
April 2014
17.30
May 2017
2
2
15
15.1
May 2017
18
18.1
April 2014
2
15.2
May 2017
18.2
April 2014
2
15.3
May 2017
18.3
April 2014
2
15.4
May 2017
18.4
May 2017
2
15.5
April 2014
18.5
April 2014
15.6
April 2014
18.6
April 2014
18.7
April 2014
2
16
16.1
May 2017
18.8
April 2014
16.2
April 2014
18.9
April 2014
16.3
April 2014
18.10
May 2017
2
16.4
April 2014
18.11
May 2017
2
16.5
April 2014
18.12
May 2017
2
16.6
April 2014
2
16.7
May 2017
19
19.1
April 2014
1
16.8
July 2015
19.2
April 2014
2
16.9
May 2017
2
16.10
May 2017
List of pages for Supplements is enclosed in page 19.2.

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.6
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision
corrected
0.3. Table of contents
Section / Item No. and Title Page
SECTION 0. ISSUANCES..................................................................................... 0.1
0.1. Record of revisions ............................................................................... 0.1
0.2. List of effective pages........................................................................... 0.4
0.3. Table of contents .................................................................................. 0.6
0.4. Table of figures..................................................................................... 0.12
SECTION 1. DESCRIPTION AND TECHNICAL DATA......................................... 1.1
1.1. Sailplane description............................................................................. 1.1
1.2. Sailplane technical data........................................................................ 1.3
1.3. Sailplane three view drawing ................................................................ 1.4
1.4. Crew mass balancing............................................................................ 1.5
SECTION 2. ASSEMBLING AND DISASSEMBLING,
SYSTEMS DESCRIPTION........................................................... 2.1
2.1. Wings assembling and disassembling.................................................. 2.1
2.1.1. Description of the wing-fuselage connection................................ 2.1
2.1.2. Wings rigging................................................................................ 2.4
2.1.3. Wings de-rigging........................................................................... 2.4
2.2. Assembling and disassembling wingtips............................................... 2.5
2.2.1. Assembling wingtips: plane or winglet.......................................... 2.5
2.2.2. Disassembling wingtips: plane or winglet ..................................... 2.5
2.2.3. Assembling and disassembling long wingtips............................... 2.7
2.3. Horizontal tailplane assembling and disassembling.............................. 2.10
2.4. Elevator mounting and dismounting...................................................... 2.12
2.5. Rudder mounting and dismounting....................................................... 2.12
2.6. Ailerons mounting and dismounting...................................................... 2.12
2.6.1. Wing aileron dismounting............................................................. 2.12
2.6.2. Long wingtip aileron dismounting ................................................. 2.13
2.7. Nose wheel mounting and dismounting................................................ 2.13
2.8. Main wheel mounting and dismounting................................................. 2.14
2.9. Main landing gear mounting and dismounting....................................... 2.17
2.10. Tail wheel mounting and dismounting................................................... 2.17
2.11. Canopy ................................................................................................. 2.18
2.12. Rudder control system.......................................................................... 2.20
2.13. Elevator, aileron and longitudinal trimming control system ................... 2.22
2.14. Airbrake control system ........................................................................ 2.26

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision No. 2 May 2017
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.7
corrected
2.15. Front instrument panel...........................................................................2.30
2.15.1. Front instrument panel mounting and dismounting .......................2.32
2.15.2. SP3 stall warning device installation.............................................2.33
2.16. Rear instrument panel...........................................................................2.34
2.16.1. Rear instrument panel mounting and dismounting........................2.35
2.17. Electric system ......................................................................................2.36
2.18. Removing rear seat pan........................................................................2.37
2.19. Tow releases control system.................................................................2.39
2.20. Battery and equipment mounting in luggage compartment ...................2.41
2.21. Sailplane drainage system ....................................................................2.42
SECTION 3. TECHNICAL SPECIFICATION,
TOLERANCES AND ADJUSTMENT............................................3.1
3.1. Tire pressure .........................................................................................3.1
3.2. Cables tension.......................................................................................3.1
3.3. Fuselage control devices motion resistance forces...............................3.1
3.4. Allowable backlashes and tolerances in mounting connections
and sailplane control systems ...............................................................3.2
3.4.1. Allowable control stick play ...........................................................3.2
3.4.2. Backlashes in the connections of torsional tubes with drivers
in aileron and airbrake control systems.........................................3.2
3.4.3. Maximum allowable backlashes on sailplane main unit
connection fittings .........................................................................3.3
3.4.4. Maximum allowable radial backlash in control surfaces hinges....3.3
3.4.5. Allowable play –airbrake plates shift............................................3.3
3.5. Adjustment of sailplane assemblies and control systems......................3.4
3.5.1. General notes ...............................................................................3.4
3.5.2. Adjustment of aileron control system in wing................................3.4
3.5.3. Adjustment of airbrake control system in wing..............................3.4
3.5.4. Adjustment of aileron control system in fuselage..........................3.4
3.5.5. Adjustment of elevator control system ..........................................3.4
3.5.6. Adjustment of cables tension in rudder control system.................3.5
3.5.7. Adjustment of airbrake control system in fuselage........................3.5
3.5.8. Adjustment of trimmer control system...........................................3.6
3.5.9. Adjustment of wheel brake............................................................3.6
3.5.10. Adjustment of rear seat pan..........................................................3.6
SECTION 4. SPECIAL TOOLS SPECIFICATION..................................................4.1
4.1. Tire pumping end...................................................................................4.1
4.2. Wingtips mounting key ..........................................................................4.1
4.3. Rear fitting assembly key ......................................................................4.2
4.4. Mounting wrench...................................................................................4.2
2
2

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.8
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision No. 2 May 2017
corrected
SECTION 5. LUBRICATION INSTRUCTION ........................................................ 5.1
5.1. General................................................................................................. 5.1
5.1.1. Rolling and slide bearings lubrication........................................... 5.1
5.1.2. Mounting elements lubrication...................................................... 5.1
5.1.3. Bowden cables lubrication............................................................ 5.1
5.1.4. Elements not requiring lubrication ................................................ 5.2
SECTION 6. SAILPLANE ALIGNMENT AND CONTROL SURFACES
DEFLECTION INSPECTION........................................................ 6.1
SECTION 7. SAILPLANE WEIGHING................................................................... 7.1
7.1. Method of weighing............................................................................... 7.1
7.2. Sailplane without pilots mass and CG position ..................................... 7.3
7.3. Calculation of sailplane without pilots CG position................................ 7.6
SECTION 8. EQUIPMENT..................................................................................... 8.1
8.1. Minimum equipment.............................................................................. 8.1
8.1.1. Airspeed indicators....................................................................... 8.2
8.1.2. Altimeters ..................................................................................... 8.2
8.1.3. Accelerometers............................................................................. 8.2
8.1.4. Stall warning unit.......................................................................... 8.3
8.1.5. Safety harnesses.......................................................................... 8.3
8.1.6. Batteries....................................................................................... 8.3
8.1.7. Tow releases................................................................................ 8.3
8.2. Additional equipment ............................................................................ 8.4
8.2.1. Variometers and related accessories ........................................... 8.5
8.2.2. Artificial horizon............................................................................ 8.5
8.2.3. Compasses .................................................................................. 8.5
8.2.4. Turn and bank indicators.............................................................. 8.6
8.2.5. Bank indicators and inverted flight bank indicators....................... 8.6
8.2.6. Stall warning device...................................................................... 8.6
8.2.7. Batteries....................................................................................... 8.6
8.2.8. Transceiver................................................................................... 8.7
8.2.9. Emergency Locator Transmitter ................................................... 8.8
8.2.10. Transponders ............................................................................... 8.8
8.3. Other additional equipment................................................................... 8.8
SECTION 9. INSPECTION OF CONTROL SURFACES BALANCE ..................... 9.1
SECTION 10. AIRWOTHINESS LIMITATIONS.................................................. 10.1
10.1. Sailplane service life........................................................................... 10.1
10.2. Service life of elements installed on sailplane..................................... 10.1
10.2.1. Crew safety harness................................................................... 10.1
10.2.2. Tow releases.............................................................................. 10.1
10.2.3. Board instruments ...................................................................... 10.1
2

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.9
corrected
SECTION 11. LIST OF MAINTENANCE DOCUMENTS OF ASSEMBLIES
APPROVED REGARDLESS OF SAILPLANE ...........................11.1
SECTION 12. CLEANING AND MAINTENANCE.................................................12.1
12.1. Canopy perspex ..................................................................................12.1
12.2. Painted exterior surfaces.....................................................................12.1
SECTION 13. SAILPLANE TRANSPORT AND STORAGE IN A HANGAR........13.1
13.1. Sailplane transport at the airfield.........................................................13.1
13.2. Storage in a hangar.............................................................................13.2
13.2.1. Sailplane lifting and moving ........................................................13.2
13.2.2. Sailplane hanging .......................................................................13.3
SECTION 14. DISMOUNTED SAILPLANE TRANSPORT...................................14.1
14.1. Transport in sailplane trailer ................................................................14.1
14.2. Transport in container..........................................................................14.1
SECTION 15. INFORMATION TABLES...............................................................15.1
15.1. Pictograms ..........................................................................................15.1
15.2. Terms of use tables.............................................................................15.2
15.2.1. Limitation table “Maximum allowed airspeed”.............................15.2
15.2.2. Limitation table „Allowed VNE values for various flight altitudes” .15.2
15.2.3. Tables „Pressure in tires” ............................................................15.2
15.2.4. Table “Manoeuvring loads and loading”......................................15.3
15.2.5. Table „Individual loading plan” ....................................................15.4
15.2.6. Table „Approved manoeuvres”....................................................15.5
15.2.7. Table „Pre- flight checklist”..........................................................15.5
15.2.8. Compass deviation table.............................................................15.6
SECTION 16. PERIODIC MAINTENANCE..........................................................16.1
16.1. General rules for periodic maintenance...............................................16.1
16.2. Periodic maintenance of SP3 stall warning device..............................16.1
16.3. Periodic maintenance of board instruments ........................................16.2
16.4. Periodic maintenance of radio and electronic equipment....................16.2
16.5. Periodic maintenance of tow releases.................................................16.2
16.6. Periodic maintenance of wheels..........................................................16.2
16.7. Rules for operations of cables.............................................................16.3
16.8. Inspection of non-accessible areas in control systems........................16.3
16.9. Inspection of main units subjected to fatigue loads .............................16.4

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.10
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision
corrected
16.10. Maintenance work and actions carried out on a sailplane................... 16.5
16.10.1. Complete structure inspection on rigged sailplane.................... 16.6
16.10.2. Inspection of instruments and pneumatic installation ................. 16.7
16.10.3. Check operation of electric turn indicator (if installed)............... 16.7
16.10.4. Check electric connection between CG tow release
and control sticks in a cockpit..................................................... 16.7
16.10.5. Check operation and correct fitting of additional installations..... 16.7
16.10.6. Verify reliable de-rigging and rigging of sailplane main units...... 16.8
16.10.7. Complete structure inspection on de-rigged sailplane............... 16.8
16.10.8. Verify mass balance of control surfaces...................................... 16.10
16.10.9. Complete sailplane weighing...................................................... 16.10
16.10.10.Perform test flight ....................................................................... 16.10
16.10.11.Check the patency of all drainage holes..................................... 16.10
SECTION 17. SAILPLANE REPAIRS.................................................................. 17.1
17.1. Introductory remarks........................................................................... 17.1
17.2. Composite structures repairing........................................................... 17.2
17.2.1. Repair conditions........................................................................ 17.2
17.2.2. Damages classification............................................................... 17.3
17.3. Typical composite structures repairs................................................... 17.10
17.3.1. Sandwich shell laminate-foam-laminate..................................... 17.10
17.3.2. Solid laminate shell..................................................................... 17.13
17.3.3. Debonding.................................................................................. 17.13
17.3.4. Fuselage central section skin repair –zone II ............................ 17.14
17.3.5. Repair of rear (sandwich) fuselage part –zone III...................... 17.15
17.3.6. Inner structure debonding........................................................... 17.20
17.4. Painting............................................................................................... 17.21
17.5. Materials for typical repairs of composite structures........................... 17.22
17.6. Non-composite parts repair................................................................. 17.24
17.6.1. Metal parts repair........................................................................ 17.24
17.6.2. Rudder control system cables replacement................................ 17.24
17.6.3. Reaming of main bolt sleeves and rear fittings........................... 17.25
17.6.4. Canopy perspex ......................................................................... 17.26
17.6.5. Parts replacement ...................................................................... 17.27
17.7. Primary and secondary structure ........................................................ 17.29
17.7.1. Primary structure........................................................................ 17.29
17.7.2. Secondary structure ................................................................... 17.30
17.8. Assemblies interchangeability............................................................. 17.30

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.11
corrected
SECTION 18. ANNEXES .....................................................................................18.1
18.1. Equipment list......................................................................................18.1
18.2. Record of sailplane weighing and determining of CG..........................18.4
18.3. Elevator, rudder and ailerons balance records....................................18.5
18.4. Calculation record of sailplane without pilots CG.................................18.8
18.5. Record of control surfaces movements...............................................18.10
18.6. Glider alignment record.......................................................................18.11
18.7. Measurement record for glider control systems friction
and activation forces............................................................................18.12
SECTION 19. SUPPLEMENTS............................................................................19.1
19.1. Introduction..........................................................................................19.1
19.2. List of inserted supplements................................................................19.1
19.3. Supplements –List of actual pages.....................................................19.2

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.12
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision No. 2 May 2017
corrected
0.4. Table of figures
Figure No. and Title Page
Fig. 1-1. Sailplane 3-view drawing.................................................................. 1.4
Fig. 2-1. Wings rigging.................................................................................... 2.3
Fig. 2-2. Assembling wingtip: plane or winglet................................................ 2.6
Fig. 2-3. Long wingtips assembling................................................................. 2.8
Fig. 2-4. Detail A of wing - long wingtip connection ....................................... 2.9
Fig. 2-5. Detail B of wing - long wingtip connection ....................................... 2.9
Fig. 2-6. Horizontal tailplane assembling........................................................ 2.11
Fig. 2-7. Nose wheel mounting....................................................................... 2.13
Fig. 2-8. Main landing gear............................................................................. 2.15
Fig. 2-9. Main landing wheel hub.................................................................... 2.16
Fig. 2-10. Canopy............................................................................................. 2.19
Fig. 2-11. Rudder control system...................................................................... 2.21
Fig. 2-12. Elevator, aileron and trimmer control system in fuselage ................. 2.23
Fig. 2-13. Aileron control system in wings......................................................... 2.25
Fig. 2-14. Airbrake control system in fuselage.................................................. 2.27
Fig. 2-15. Airbrake control system in wing........................................................ 2.29
Fig. 2-16. Front instrument panel installation diagram...................................... 2.31
Fig. 2-17. SP3 stall warning device installation................................................. 2.33
Fig. 2-18. Rear instrument panel installation diagram....................................... 2.35
Fig. 2-19. Scheme of electric installation .......................................................... 2.36
Fig. 2-20. Rear seat pan mounting ................................................................... 2.38
Fig. 2-21. Tow releases control system ............................................................ 2.40
Fig. 2-22. Battery mounting in sailplane luggage compartment........................ 2.41
Fig. 2-23. Sailplane drainage holes layout scheme .......................................... 2.42
Fig. 3-1. Driver connection scheme................................................................ 3.2
Fig. 4-1. Tire pumping end.............................................................................. 4.1
Fig. 4-2. Wingtips mounting key...................................................................... 4.1
Fig. 4-3. Rear fitting assembly key.................................................................. 4.2
Fig. 5-1. Lubrication scheme........................................................................... 5.3
Fig. 6-1. Sailplane alignment and control surfaces deflection......................... 6.2
Fig. 7-1. Sailplane weighing............................................................................ 7.2
Fig. 7-2. CG range limits for a sailplane without pilots.................................... 7.4
Fig. 7-3. Location of balancing weight in sailplane tail.................................... 7.5
Fig. 7-4. Battery mounting in sailplane tail...................................................... 7.5
Fig. 9-1. Inspection of control surfaces balance.............................................. 9.3
2
1

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 0.
ISSUANCES
Issue II April 2014
Revision
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 0.13
corrected
Fig. 13-1. Sailplane lifting and moving.............................................................13.2
Fig. 13-2. Sailplane hanging areas..................................................................13.3
Fig. 17-1. Zoning and material specification for fuselage repairs ....................17.4
Fig. 17-2. Zoning and material specification for wing repairs ..........................17.5
Fig. 17-3. Material specification for vertical stabilizer repairs ..........................17.6
Fig. 17-4. Material specification for rudder repairs ..........................................17.7
Fig. 17-5. Material specification for horizontal stabilizer repairs......................17.8
Fig. 17-6. Material specification for elevator repairs........................................17.9
Fig. 17-7. Damage to the sandwich outer layer...............................................17.10
Fig. 17-8. Repair of damaged sandwich outer layer........................................17.10
Fig. 17-9. Damage to sandwich outer layer and foam.....................................17.11
Fig. 17-10. Repair of damaged sandwich outer layer and foam........................17.11
Fig. 17-11. Through damage.............................................................................17.12
Fig. 17-12. Repair of through damage...............................................................17.12
Fig. 17-13. Solid laminate shell damage ...........................................................17.13
Fig. 17-14. Repair of solid laminate shell ..........................................................17.13
Fig. 17-15. Wet repair........................................................................................17.14
Fig. 17-16. Dry repair ........................................................................................17.15
Fig. 17-17. Damage to sandwich outer shell.....................................................17.15
Fig. 17-18. Repair of damage to sandwich outer shell ......................................17.15
Fig. 17-19. Damage to sandwich outer shell and foam .....................................17.16
Fig. 17-20. Repair of damage to sandwich outer shell and foam ......................17.16
Fig. 17-21. Sandwich structure trough damage.................................................17.17
Fig. 17-22. Repair of sandwich structure trough damage..................................17.17
Fig. 17-23. Damage to sandwich outer shell, detail “A” .....................................17.18
Fig. 17-24. Repair of damage to sandwich outer shell, detail “A” ......................17.19
Fig. 17-25. Inner structure debonding ...............................................................17.20
Fig. 17-26. Repair of inner structure debonding................................................17.20
Fig. 17-27. Reaming of connecting spars main bolt sleeves and rear fittings....17.25
Fig. 17-28. Way to avoid further cracking of perspex........................................17.26

SECTION 0.
ISSUANCES
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 0.14
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision
corrected
Intentionally left blank

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 1.
DESCRIPTION AND
TECHNICAL DATA
Issue II April 2014
Revision
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 1.1
corrected
SECTION 1.
DESCRIPTION AND TECHNICAL DATA
1.1. Sailplane description
SZD-54-2 „Perkoz” is a two-seat sailplane made of composite: primary
structure in glass-epoxy, with some components (exchangeable wingtips, canopy
frame, rudder) in carbon-epoxy, designed according to certification specifications
CS-22.
Two-panel wings of tapered outline with exchangeable wingtips: plane type
(Category U and A), winglets (Category U only) or long with winglets (increasing wing
span to 65,62 ft, Category U only). NN-8 laminar aerofoil. Sandwich skin composite-
foam-composite. Wing spar flanges of glass roving reinforced composite. Spar roots
joined together with horizontal main bolt.
Wing ailerons of 20% chord ratio, sandwich structure, mounted on five hinges,
driven by single input. Long wingtip ailerons with constant chord, sandwich structure,
mounted on two hinges and additionally supported on aileron clutch.
Two-plate airbrakes protruding from wing top surface only. Panels equipped
with adjustable laminate cover straps, tightened with springs.
Connection of aileron and airbrake control systems is done automatically when
wings are mounted to the fuselage.
Monocoque structure fuselage, integral with fin. Central part comprises a
frame with formers (main front former, rear upper and lower former), upper ceiling
and luggage boot floor.
Tail unit in conventional arrangement, with horizontal tailplane shifted slightly
to the rear. Stabilizer and fin of sandwich structure. Elevator of sandwich structure,
mounted on six hinges, driven by single input, mass balanced. Composite carbon-
epoxy rudder with horn type balance –aerodynamic and mass.
Connection of elevator control system is done automatically by sliding elevator
lever slit over a roller on a lever mounted in the fuselage. System is equipped with
spring type longitudinal trim control (trimmer).
Monorail, fixed landing gear. Shock-absorbed main wheel (350×135 mm)
equipped with hydraulic brake. Nose (255×110 mm) and tail (200×50 mm)
wheels non-cushioned, without brakes.
The cockpit with tandem seats arrangement equipped with one-piece canopy,
side-opening to the right. Rotary hinges situated on RH cockpit board. Mounted to
fittings laminated to fuselage shell. Emergency jettison mechanism located on
canopy frame, on the right hand side. The canopy equipped with “Röger hook”.

SECTION 1.
DESCRIPTION AND
TECHNICAL DATA
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 1.2
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision No. 2 May 2017
corrected
Seated pilot attitude in a cockpit. Fixed back rest at front seat with no
regulation. Seat pan of rear seat adjustable on ground (vertical position and distance
from pedals). Pedals at front seat adjustable in-flight, pedals at rear seat –fixed. At
both seats additional back cushions are provided, not fastened to back rest, to
enhance comfort for short pilots.
Instrument panels located at front and rear seats, the latter –optional.
Sailplane minimum equipment is mounted in the front instrument panel and includes:
airspeed indicator with range of indications 0 ÷ 160 or 200 kn
altimeter with range of indications 0 ÷ 30 000 ft
accelerometer with range of indications from -5 to +7 g
(item removed).
Additionally front instrument panel can be equipped with:
compass
electrical turn indicator with bank indicator
bank indicator for inverted flight
total energy compensated variometer with range ±10 kn (recommended)
variometer’s compensating vessel (recommended)
variometer ±60 kn
transceiver
transponder
stall warning unit SP3.
and other equipment listed in Section 8. of this Manual.
According to specification CS-22 equipment in rear instrument panel isn’t
necessary (for second pilot). However, the Type Certificate Holder suggest to install:
airspeed indicator with range of indications 0 ÷ 160 or 200 kn
altimeter with range of indications 0 ÷ 30 000 ft
accelerometer with range of indications from -5 to +7 g
total energy compensated variometer with range ±10 kn
variometer’s compensating vessel
Additionally rear instrument panel can be equipped with:
compass
electrical turn indicator with bank indicator
bank indicator for inverted flight
variometer ±60 kn
and other equipment listed in Section 8. of this Manual.
2
2

SZD-54-2
„Perkoz”
TECHNICAL SERVICE MANUAL
SECTION 1.
DESCRIPTION AND
TECHNICAL DATA
Issue II April 2014
Revision No. 2 May 2017
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
page 1.3
corrected
1.2. Sailplane technical data
Span
57,42
65,62
[ft]
Length
27,69
[ft]
Height (fin with tail wheel)
6,73
[ft]
Root chord
4,27
[ft]
Outboard chord
1,77
0,98
[ft]
Mean standard chord (MSC)
3,25
3,15
[ft]
Wing area
176,10
186,22
[ft2]
Aspect ratio
18,70
23,135
Tailplane span
11,15
[ft]
Empty sailplane mass (brand new sailplane)
827 + 22
838 + 22
[lb]
An empty sailplane is defined as a sailplane with minimum equipment
specified in the item 8.1. of this Manual, without balance weights and any load (crew,
parachutes, baggage).
Maximum in-flight mass
In Category „U”
1356
[lb]
In Category „A”
1301
[lb]
2

SECTION 1.
DESCRIPTION AND
TECHNICAL DATA
TECHNICAL SERVICE MANUAL
SZD-54-2
„Perkoz”
page 1.4
Allstar PZL Glider Sp. z o.o.
Doc No. 542.4.02
Issue II April 2014
Revision
corrected
1.3. Sailplane three view drawing
Fig. 1-1. Sailplane 3-view drawing