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Allstar PZL Glider SZD-54-2 Perkoz, Technical & Service Manual

The Allstar PZL Glider SZD-54-2 Perkoz is a high-performance, two-seat glider designed for both recreational and competitive flying. For comprehensive information on maintenance and service procedures, download the free Technical & Service Manual from manualshive.com. This manual provides detailed instructions for the optimal operation of the glider.

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SECTION 17. 

SAILPLANE REPAIRS 

TECHNICAL SERVICE MANUAL 

SZD-54-2 
„Perkoz” 

 

page 17.8

 

Allstar PZL Glider Sp. z o.o. 

Doc No. 542.4.02 

Issue II 

April 2014 

Revision   

 

corrected 

Zone III 

– horizontal stabilizer and elevator 

 
 

 

 
 

Fig. 17-5.  Material specification for horizontal stabilizer repairs 

 

Summary of Contents for SZD-54-2 Perkoz

Page 1: ...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 VE...

Page 2: ...n 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...

Page 3: ...e 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 A...

Page 4: ...AL 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 Approv...

Page 5: ...ERVICE 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 Approv...

Page 6: ...l 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 A...

Page 7: ...14 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...

Page 8: ...nection 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 wingle...

Page 9: ...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...

Page 10: ...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...

Page 11: ...s 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...

Page 12: ...rform 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 c...

Page 13: ...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 al...

Page 14: ...ig 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...

Page 15: ...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 Rep...

Page 16: ...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...

Page 17: ...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 fuselag...

Page 18: ...ations 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 compens...

Page 19: ...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 br...

Page 20: ...N 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 Sailp...

Page 21: ...le weights 13 2 lb each are provided for crew mass balancing according to sailplane loading plan Weights are screwed down to plugs situated in the floor in front of front seat Mounting the weight cons...

Page 22: ...SECTION 1 DESCRIPTION AND TECHNICAL DATA TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 1 6 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left blank...

Page 23: ...th safety pin Wings are joined together by spar roots overlapping each other wherein each of spar root through the pin 1 is embedded in the sleeve 2 which is mounted in the root rib 24 of the opposite...

Page 24: ...l 6 Terminal of torque tube in airbrake control 7 Aileron driving latch pin 8 Airbrake driving latch pin 9 Ball socket in the fuselage frame for the main bolt 10 Main bolt 11 Handle of main bolt 12 Mo...

Page 25: ...z TECHNICAL SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision No 1 July 2015 Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 3 corrected Fig 2 1 Win...

Page 26: ...e control stick and airbrake control pushrod 5 Connect the spar roots with the main bolt 10 inserting simultaneously the bolt in the ball socket 9 fastened in the frame 6 Lock the fuselage rear pins 1...

Page 27: ...6 Operation sequence in assembling wingtips plane or winglet 1 Insert spar root of wingtip in a spar socket on wing side 2 Pull down the bolt 3 onto stop by means of screwed in key 6 hold in the unloc...

Page 28: ...TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 2 6 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected 1 Spar pin 2 Nest socket 3 Bolt 4 Pin 5 Sleeve 6 Wingtip mounting k...

Page 29: ...sequence in assembling long wingtips 1 Insert spar root of wingtip in a spar socket on wing side 2 Set the same deflection for wing and wingtip ailerons 3 Pull down the bolt 3 onto stop by means of s...

Page 30: ...ZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Fig 2 3 Long wingtips assembling Legend to Fig 2 3 2 4 2 5 1 Spar pin 2 Nest socket 3 Bolt 4 Pin 5 Sleeve 6 Outer part of aile...

Page 31: ...CTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 9 corrected Fig 2 4 Detail A of wing long wingtip connection Fig 2...

Page 32: ...upper and the elevator in lower position facilitates automatic connection of elevator control by aligning cut out in the lever 9 with lever roll 8 Correct connection between levers 8 and 9 must be ve...

Page 33: ...4 02 page 2 11 corrected Fig 2 6 Horizontal tailplane assembling 1 Stabilizer fastening vertical bolt 2 Special safety pin 3 Fuselage fitting 4 Stabilizer pin 5 Sleeve 6 Stabilizer mounting web 7 Rudd...

Page 34: ...is presented in Fig 2 11 Rudder 13 dismounting is possible after uncovering the inspection hole 22 on the LH side of rudder Dismounting follows by unscrewing the castellated nut 10 after removing safe...

Page 35: ...2 13 2 Remove aileron axially towards wingtip root Mounting to be accomplished in reverse sequence 2 7 Nose wheel mounting and dismounting Method of nose wheel mounting is presented in Fig 2 7 Dismou...

Page 36: ...hout disconnecting the hose 7 3 Unscrew axle screw 26 4 Remove wheel axle 5 Mounting to be accomplished in reverse sequence NOTE Axle screw 26 should be located on the side of the wheel brake Legend t...

Page 37: ...2 Perkoz TECHNICAL SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 15 corrected Fig 2 8 Main landi...

Page 38: ...4 02 Issue II April 2014 Revision corrected For dismounting of tire and inner tube Fig 2 9 unscrew screws 4 NOTE Before assembling both halves of hub and tire inner tube is to be slightly pumped Oper...

Page 39: ...ove bolts 18 4 Remove cotter pins securing bolts 20 and the bolts themselves 5 Dismounting of shock absorbers 23 is done after removal of cotter pins from bolts 25 and the bolts themselves Disassembli...

Page 40: ...rs 1 and pull rod 5 when lever 1 is pushed forward by pilot from either front or rear seat In order to prevent inadvertent too easy canopy jettison device actuation the lever 1 is connected to canopy...

Page 41: ...D 54 2 Perkoz TECHNICAL SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 19 corrected Fig 2 10 Cano...

Page 42: ...ving bolt 8 Rear foot pedals 9 Rudder lower fitting 10 Castellated nut 11 Front foot pedals assembling 12 Rudder upper hanging bolt 13 Rudder 14 Rudder driving cable pulleys 15 Rear rudder pedals driv...

Page 43: ...erkoz TECHNICAL SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 21 corrected Fig 2 11 Rudder contr...

Page 44: ...htener 21 Trimmer spring 22 Trimmer locking trigger only 2nd version Sailplane does not have classic trimmer i e adjustable flap at the elevator It has spring balancing device which for simplicity of...

Page 45: ...ERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 23 corrected Fig 2 12 Elevator aileron and trimmer...

Page 46: ...13 1 Long pushrod in left wing 2 Long pushrod in right wing 3 Pushrod 4 Aileron 5 Aileron driving lever 6 Aileron hinges 7 Castellated nut 8 Pushrod pass 9 Aileron intermediate driving lever 10 Ailero...

Page 47: ...TECHNICAL SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 25 corrected Fig 2 13 Aileron control s...

Page 48: ...26 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 2 May 2017 corrected 2 14 Airbrake control system Legend to Fig 2 14 1 Airbrake driving pushrod in cockpit 2 Airbrake dr...

Page 49: ...SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision No 2 May 2017 Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 27 corrected Fig 2 14 Airbrake cont...

Page 50: ...ue II April 2014 Revision corrected Legend to Fig 2 15 1 Adjustable pushrod 2 Special adjustable pushrod 3 Bevel gears assembly 4 Airbrake driving latch pin connected to bevel gears assembly 5 Interme...

Page 51: ...TECHNICAL SERVICE MANUAL SECTION 2 ASSEMBLING DISASSEMBLING SYSTEMS DESCRIPTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 29 corrected Fig 2 15 Airbrake control...

Page 52: ...ipe 6 Static air pressure conduit 7 Total air pressure conduit 8 Electrical turn indicator 9 Airspeed indicator 10 Variometer 11 Accelerometer 12 Altimeter 13 Compass 14 Variometer compensator standar...

Page 53: ...April 2014 Revision No 2 May 2017 Allstar PZL Glider Sp z o o Doc No 542 4 02 page 2 31 corrected Fig 2 16 Front instrument panel installation diagram C Total pressure S Static pressure W Compensated...

Page 54: ...uated on both sides lower part of the casing on edges of the canopy outline Next raise gently front of the casing and move it towards yourself 2 Disconnect static 6 and total 7 pressure conduits 3 Dis...

Page 55: ...age 2 33 corrected 2 15 2 SP3 stall warning device installation Warning device SP3 is an optional accessory Fig 2 17 SP3 stall warning device installation 1 SP3 stall indicator 2 Instrument s panel sw...

Page 56: ...om sailplane on which there is mounted a mandatory front cabin headrest Legend to Fig 2 18 1 Instrument panel 2 Instrument panel casing 3 Static pressure vent 4 Air intake and total air pressure vent...

Page 57: ...iagram C total pressure S static pressure W compensated pressure 2 16 1 Rear instrument panel mounting and dismounting Operation sequence in dismounting 1 Disconnect conduits 5 and 6 from connector 19...

Page 58: ...g device circuit Automatic fuse 106 P30 1A AWG 24 0 0023 A cmil Transceiver circuit Automatic fuse 106 P30 4A AWG 20 0 004 A cmil Transponder circuit Automatic fuse 106 P30 2A AWG 20 0 002 A cmil ELT...

Page 59: ...transceiver or LEDs flashing at stall warning device SP3 provided it is installed Extending electrical installation according to above scheme use copper multi wire insulated aviation conductors LYc L...

Page 60: ...r Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Fig 2 20 Rear seat pan mounting 1 Seat pan 2 Rear tube with a knob sliding out the supporting bolts 5 3 Front supporting tube 4 Guide...

Page 61: ...h total handle 3 pinching in front seat and independently handle 4 in rear seat Recommended adjustment is to leave few millimetres play of additional movement at the end of CG tow release lever 2 for...

Page 62: ...EMBLING DISASSEMBLING SYSTEMS DESCRIPTION TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 2 40 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Fig 2 21 Tow releases co...

Page 63: ...Fig 2 22 Battery mounting in sailplane luggage compartment On the floor of the luggage compartment it is possible to install additional equipment of total weight including two batteries up to 44 lb T...

Page 64: ...4 Revision corrected 2 21 Sailplane drainage system Fig 2 23 Sailplane drainage holes layout scheme Presented in Figure sailplane drainage system consists of Five 0 16 drainage holes in fuselage shell...

Page 65: ...18 Fig 2 11 11 4 4 lbf 3 3 Fuselage control devices motion resistance forces Normal motion resistance forces values expressed in lbf measured at the centre of handles foot pedals plate in neutral posi...

Page 66: ...at self aligning bearing is the cause of excessive control system play it should be replaced together with a part in which it is mounted 3 4 2 Backlashes in the connections of torsional tubes with dri...

Page 67: ...ctions is for diameters up to 0 71 inclusive 0 004 for diameters greater than 0 71 0 006 3 4 4 Maximum allowable radial backlash in control surfaces hinges Allowable radial backlash in elevator rudder...

Page 68: ...ib 3 5 3 Adjustment of airbrake control system in wing Adjustment of airbrake control system in wing Fig 2 15 is done at pushrod end 1 near the connection with airbrake arm driving lever 7 in airbrake...

Page 69: ...3 0 or 3 2 mm 0 118 or 0 126 Foot pedals by front and rear seat are provided with adjustable deflection limiters Adjustment of rudder deflections is done by using pedals deflection limiters When front...

Page 70: ...t pushrod 17 end by tightener 20 regulation screw Operation sequence in adjusting dismount tailplane set trimmer to nose heavy position Force required to move control stick to neutrum position should...

Page 71: ...Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 4 1 corrected SECTION 4 SPECIAL TOOLS SPECIFICATION 4 1 Tire pumping end Fig 4 1 Tire pumping end 4 2 Wingtips mounting key Directions for us...

Page 72: ...Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 1 July 2015 corrected 4 3 Rear fitting assembly key Directions for use the key is presented in item 2 1 Fig 2 1 pos 21 Fig 4 3 Rear fitting ass...

Page 73: ...bricated with general purpose grease T 43 PN 72 C 96134 Equivalent to above mentioned are American greases Shell Alvania G2 Alvania R2 Mobil Mobilux 2 Esso Beacon 2 NOTE All these greases may be mixed...

Page 74: ...utch 2 Aileron driving latch pin bearings in wing root rib 3 Aileron and elevator control systems bearings 4 Elevator hinges 5 Sleeves in wing root rib together with spar root pins and wing front pins...

Page 75: ...SZD 54 2 Perkoz TECHNICAL SERVICE MANUAL SECTION 5 LUBRICATION INSTRUCTION Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 5 3 corrected Fig 5 1 Lubrication scheme...

Page 76: ...SECTION 5 LUBRICATION INSTRUCTION TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 5 4 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left blank...

Page 77: ...EFLECTION INSPECTION Sailplane alignment and control surfaces deflection inspection should be performed in accordance to Fig 6 1 Forms of records of sailplane alignment and control surfaces movements...

Page 78: ...SURFACES DEFLECTION INSPECTION TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 6 2 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 2 May 2017 corrected Fig 6 1 Sailplane ali...

Page 79: ...pport During weighing it should be used a Record of sailplane weighing and determining of CG which is provided in Section 18 Weighing should be done in sailplane configuration with plane wingtips not...

Page 80: ...in a horizontal distance between nose wheel axle and reference datum adopted in calculations is 63 19 m sailplane mass lb w1 indication of front scale lb w2 indication of rear scale lb In case of seri...

Page 81: ...m 1 4 In sailplane tail vertical stabilizer ballast should be placed in cylindrical container inserted into wall opening Fig 7 3 As a rear fixed ballast may also be used a battery mounted in container...

Page 82: ...ANE WEIGHING TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 7 4 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 2 May 2017 corrected Fig 7 2 CG range limits for a sailplane...

Page 83: ...ril 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 7 5 corrected Fig 7 3 Location of balancing weight in sailplane tail Fig 7 4 Battery mounting in sailplane tail 1 Weight of lead shot...

Page 84: ...f sailplane without pilots CG a pattern of which is presented in Section 18 and based on current and previous Equipment list and previous Record of sailplane weighing and determining of CG or Calculat...

Page 85: ...tem 7 2 Following formulas for mass of front and rear ballast should be used interchangeably i e they are true only if one of the ballast has changed either front or rear Front ballast mass mbn determ...

Page 86: ...equipment changing has a mass mbp 860 lb and corresponding CG position Xbp 30 3 in To bring it into correct Xbp position ballast should be placed on back of sailplane at position shown in Fig 7 3 Xbp...

Page 87: ...ollowing instruments in the instrument panel at front seat airspeed indicator with range of indications 0 160 or 200 kn altimeter with range of indications 0 30 000 ft accelerometer with range of indi...

Page 88: ...5 2 TS 10 210 03 3 15 6 FMS 4 TS 10 210 15 2 24 7 FMS 4 TS 10 210 19 It is mandatory to mark airspeed indicator dial in accordance with scheme specified in item 2 3 in Flight Manual 8 1 2 Altimeters...

Page 89: ...Gadringer Lap belt 540202 EASA 21O 10039345 TCDS 40 070 32 Shoulder belt 270002 EASA 21O 10039416 TCDS 40 071 05 Crotch belt 130302 EASA 21O 10039342 TCDS 40 072 4 ZS Je w Lap belt J5 10 00 TCDS 40 07...

Page 90: ...equipment mounting must be done in accordance with instructions given in item 2 20 Mounting in other places will require from Type Certificate Holder to develop appropriate instruction and approve it...

Page 91: ...ype Certificate Approval PZL KWEC 2 Certified with variometer Allstar PZL Glider K 1 tube Normalized part Compensating vessels Manufacturer Type Certificate Approval PZL TM 420 Certified with sailplan...

Page 92: ...ype Certificate Approval PZL PH 01 Normalized part Winter QM I II or III Falcon Gauge 2 24 SI 2Q 8 2 6 Stall warning device Manufacturer Type Certificate Approval LAMERS S T U Allstar PZL Glider SP3 C...

Page 93: ...2 24 AR 4201 EASA 21O 10038538 JTSO 10 911 87 2 24 AR 6201 EASA 21O 1249 ETSO 2C37c 2C38e Fliser Electronic 2 24 ATR 600 LBA 0 10 911 106 JTSO ATR 600 A LBA 0 10 911 114 JTSO ATR 720 TCDS 10 911 70 A...

Page 94: ...on sailplane Manufacturer Type Certificate Approval Becker 2 24 BXP 6401 2 02 Mode S 50000ft EASA 21O 322 ETSO TSO 2C112a 2 24 BXP 6401 1 01 Mode S 15000ft 2 24 ATC4401 1 250 Mode A and C 50000ft JTSO...

Page 95: ...n such way that movement resistance is as small as possible when deflecting NOTE Mount aileron and elevator on two hinges in a way to prevent excessive elastic bending 3 Calculate allowable value of b...

Page 96: ...r repair should correspond to the mass before repair with an acceptable mass increments main aileron 0 055 lb wingtip aileron 0 022 lb rudder 0 110 lb elevator 0 055 lb When making repairs pay attenti...

Page 97: ...z TECHNICAL SERVICE MANUAL SECTION 9 INSPECTION OF CONTROL SURFACES BALANCE Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 9 3 corrected Fig 9 1 Inspection of control su...

Page 98: ...TION 9 INSPECTION OF CONTROL SURFACES BALANCE TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 9 4 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left bl...

Page 99: ...older 10 2 Service life of elements installed on sailplane 10 2 1 Crew safety harness Service life of crew safety harness in accordance with limitations specified by manufacturer of harness 10 2 2 Tow...

Page 100: ...SECTION 10 AIRWORTHINESS LIMITATIONS TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 10 2 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left blank...

Page 101: ...DOCUMENTS OF ASSEMBLIES APPROVED REGARDLESS OF SAILPLANE 1 Tow releases operating instructions 2 Board instruments operating instructions 3 Main landing wheel and hydraulic brake accessories operatin...

Page 102: ...TENANCE DOCUMENTS OF ASSEMBLIES APPROVED REGARDLESS OF SAILPLANE TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 11 2 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected I...

Page 103: ...ins or oil type contamination it is allowed to add to water small amount of detergent or aqueous solution of soap After washing rinse thoroughly wipe with soft clean cloth and allow to dry 12 2 Painte...

Page 104: ...SECTION 12 CLEANING AND MAINTENANCE TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 12 2 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left blank...

Page 105: ...ailplane can also roll on the wheels forward and backward Press the tail or lift the front part of fuselage when turning During sailplane transport canopy must be closed and secured leaving windows op...

Page 106: ...If the sailplane is stored in fully assembled state the ends of wings should be supported Lubricate fittings and metal parts Put on individual covers on main units Set the fuselage in profiled support...

Page 107: ...ports 3 with minimum width of 2 supporting wings in root rib planes placed on hydraulic lifts NOTE Sailplane cannot be lifted by horizontal stabilizer and by wings in different way as Manual provides...

Page 108: ...13 SAILPLANE TRANSPORT AND STORAGE IN A HANGAR TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 13 4 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left...

Page 109: ...lized with bracket as well or with tape and by its main landing and tail wheel elements For transport the following should be done plane wingtips mounted on the wings control stick immobilized by safe...

Page 110: ...SECTION 14 DISMOUNTED SAILPLANE TRANSPORT TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 14 2 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Intentionally left blank...

Page 111: ...ocking system through lever rotating Aerodynamic brake control Front and rear handle of the airbrake control pushrod Canopy lock LH side on canopy opening handles Emergency canopy jettison RH side on...

Page 112: ...ument panel close to airspeed indicator 15 2 2 Limitation table Allowed VNE values for various flight altitudes Flight altitude 1000 ft 0 9 8 13 1 16 4 19 7 23 0 26 2 29 5 32 8 U VNE IAS kn mph 132 15...

Page 113: ...arachute mass front seat m1 max 242 lb min 121 lb rear seat m2 max 242 lb Application of balancing weights m1 m2 weights One Pilot on Board 121 139 lb 26 4 lb 139 154 lb min 13 2 lb 154 lb acceptable...

Page 114: ...y 2017 corrected 15 2 5 Table Individual loading plan For every individual sailplane after every change to the mass of sailplane without pilots resulting of equipment modification or airframe repair t...

Page 115: ...ear seat 15 2 7 Table Pre flight checklist PRE FLIGHT CHECKLIST 1 No loose items in a cockpit CHECK 2 Parachutes PUT ON 3 Safety belts FASTEN 4 Controls full deflection CHECK 5 Airbrakes CLOSE AND LOC...

Page 116: ...L SERVICE MANUAL SZD 54 2 Perkoz page 15 6 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected 15 2 8 Compass deviation table Location Front and rear instrument panel cl...

Page 117: ...riately approved Part 145 Part M F etc maintenance organization At every sailplane rigging the mating parts should be lubricated see Section 5 Lubrication instruction Completed maintenance work must b...

Page 118: ...ce and periodic maintenance for GM510 accelerometer is to be done in accordance with technical requirements specified in the document No 542 3 10 01 Service and periodic works of additional equipment...

Page 119: ...Bowden housing is to be done in accordance with item 5 1 3 Replacement of cables and repair of guides and pulleys should be certified in accordance with applicable regulations In pre flight inspectio...

Page 120: ...olt 1 Fig 2 6 7 wing spars 27 at the root rib 24 Fig 2 1 8 spar root 27 end in a place of spar fitting 22 installation Fig 2 1 9 place of installation front pins 3 Fig 2 1 rear fitting 14 sockets Fig...

Page 121: ...hard landing is an indication for mandatory structure overhaul in accordance with the specification below The structure overhaul is mandatory also after exceedance of operation limitations maximum air...

Page 122: ...son of canopy by test X X 9 Check correct connection between sailplane units and reliable locking at joint points X X X 10 Check the backlash in joints at wing fuselage connection This is accomplished...

Page 123: ...e control surfaces Section 6 X X X 16 10 2 Inspection of instruments and pneumatic installation Check visually board instruments their mounting in instrument panel technical condition dials neutral po...

Page 124: ...them Fig 2 1 XZ XZ XZ 3 Verify main bolt 10 connecting spars with frame pins 1 in spar roots front pins 3 and locking pins 18 at rear fittings as well as condition of elastic locking claws 17 Fig 2 1...

Page 125: ...d ribs condition of rudder bottom and top hinges Check sockets mating with bolts 7 condition and fixing in the rudder lower fitting 9 as well as condition of lever 5 and its suspension Fig 2 11 For th...

Page 126: ...m 3 1 Check condition of nose and tail wheel tires Check smooth rotation of the wheels no jams X X X 17 Verify condition of cables in accordance with guidelines of item 16 7 X X X 16 10 8 Verify mass...

Page 127: ...or the composite structures repair based on approved repair procedure Damages which the possibility of repair by the abovementioned organizations themselves are excluded are given in item 17 2 2 Compl...

Page 128: ...d in the room for a minimum 10 hours that is until complete composite hardening It is required after hardening that repaired sites were heated for 15 hours at 122 till 140 F Temperature measurement sh...

Page 129: ...ed into 3 zones The table below shows for guidance types and size of defects for each zone Size of defect in No Type of defect ZONE I ZONE II ZONE III 1 Holes and dents 6 6 4 33 along assembly or at s...

Page 130: ...airs in the following cases are only performed by Type Certificate Holder a fittings torn out or damaged composite structure white spots around main fittings b broken spar flange c damaged wing root r...

Page 131: ...lstar PZL Glider Sp z o o Doc No 542 4 02 page 17 5 corrected Zone I wing Zone III aileron wingtip long short plane or winglet For wingtips structure description W 1 applies to winglet W 2 applies to...

Page 132: ...NICAL SERVICE MANUAL SZD 54 2 Perkoz page 17 6 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Zone III vertical stabilizer and rudder Fig 17 3 Material specificatio...

Page 133: ...2 Perkoz TECHNICAL SERVICE MANUAL SECTION 17 SAILPLANE REPAIRS Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 17 7 corrected Fig 17 4 Material specification for rudder r...

Page 134: ...AL SERVICE MANUAL SZD 54 2 Perkoz page 17 8 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected Zone III horizontal stabilizer and elevator Fig 17 5 Material specificati...

Page 135: ...Perkoz TECHNICAL SERVICE MANUAL SECTION 17 SAILPLANE REPAIRS Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 17 9 corrected Fig 17 6 Material specification for elevator...

Page 136: ...ating or gluing by degreasing grinding with sandpaper grit size approx 180 and dust removal materials protection from grease dirt and moisture proper and adequate dosage of hardener working life of mi...

Page 137: ...int coating according to item 17 4 17 3 1 2 Damage to sandwich outer layer with foam damaged Fig 17 9 Damage to sandwich outer layer and foam Fig 17 10 Repair of damaged sandwich outer layer and foam...

Page 138: ...17 12 laminate inner layer part on a piece of polyethylene foil harden fit into hole in the shell grind surfaces to be joined and paste renovated inner layer part acc to Fig 17 12 fit the foam into th...

Page 139: ...secure the hole by sticking the supporting plate of thin composite or plywood to the shell on its inner side Fig 17 14 and pull it upward with wire or suction cup after plate glue joint hardening lami...

Page 140: ...e 3 92125 make edge chamfer 30 h stick composite supporting plate from the inner side laminate fabrics acc to Fig 17 1 and Fig 17 15 NOTE Instead of the last layer 92140 apply two layers of fabric 921...

Page 141: ...Sp z o o Doc No 542 4 02 page 17 15 corrected Fig 17 16 Dry repair 17 3 5 Repair of rear sandwich fuselage part zone III 17 3 5 1 Area excluding detail A on Fig 17 1 17 3 5 1 1 Damage to sandwich oute...

Page 142: ...sition with microballoon Laminate 2 layers of 92145 fabric keeping direction acc to Fig 17 1 Size of first layer should cover the outer contour of chamfer in original 92145 layers Use peel ply Leave f...

Page 143: ...ructure check if inner shell is not damaged Make chamfer on outer shell acc to Fig 17 18 Fit the new foam into the hole and paste it on composition with microballoon to inner shell and core material F...

Page 144: ...ach direction Stick supporting plate on composition with aerosil Pull it outwards by wire or suction cup harden glue joint Widen outer shell and foam hole in fuselage axis by c 3 6 Chamfer outer shell...

Page 145: ...outer shell Chamfer outer shell acc to Fig 17 18 Fabric 92110 should not be chamfered cut acc to hole in outer shell Fit a foam part A to the web of connection layer paste it on composition with micro...

Page 146: ...e debonding Fig 17 25 the repair should be performed as follows cut out the debonded part of inner structure if there is an access precisely clean repair zone remove old glue joint and grind expected...

Page 147: ...t straight edge After grinding with sandpaper 220 spray two times crosswise polyurethane or acrylic enamel Sailplane outer surfaces should be painted with white paint not getting yellow apart from win...

Page 148: ...sed as a glue in a thicker glue joint one of the filling materials is to be added Composition lifetime depends on the hardener used and the temperature Apart from above mentioned laminating compositio...

Page 149: ...is to be filled with PCV foam that is in common use in aviation industry with density of 3 7 lb ft3 or 2 5 lb ft3 in accordance to notes given in the figures Instead of foam recommended by manual oth...

Page 150: ...ions specified by paint products manufacturer 17 6 2 Rudder control system cables replacement In rudder control system ref Fig 2 11 following cables are used 1 Cable item 16 2 5 mm 0 098 7 x 7 acc to...

Page 151: ...ming at connecting spars main bolt sleeves and connecting wing to fuselage rear fittings general rule is obligatory to keep the same type of fit as before New bolt and locking pins should be ordered f...

Page 152: ...de of organic glass methyl polymethacrylate In case of inner minor microcracks appearance caused by ageing of material exposed to sunlight the only recommendation is to replace whole canopy or perspex...

Page 153: ...ter 3rd sleeves reaming III d 22 75 0 896 f7 2 Locking pin item 18 Fig 2 1 with dimensions a nominal d 14 0 551 f7 b after 1st reaming I d 14 1 0 555 f7 c after 2nd reaming II d 14 2 0 559 f7 d after...

Page 154: ...Additionally it is possible to replace wing empennage and fuselage complete shells or their parts This replace could be done only with original tooling by sailplane manufacturer or with tooling appro...

Page 155: ...t and right 25 Fig 2 1 2 Wings spars 27 Fig 2 1 3 Root ribs 24 Fig 2 1 4 Aileron 4 Fig 2 13 5 Wingtip aileron 9 Fig 2 3 6 Front main former 27 Fig 2 8 7 Rear lower former 28 Fig 2 8 8 Horizontal stabi...

Page 156: ...wing lower surface 2 inspection openings at vertical stabilizer 3 Canopy sliding windows 17 8 Assemblies interchangeability Manufacturer provides production interchangeability of following assemblies...

Page 157: ...t The list includes sailplane equipment at day of signing Mass data from the list are also used after changing equipment to determine the mass mbp and CG position Xbp of sailplane without pilots with...

Page 158: ...Stall warning unit SP3 5 Compass 6 Inverted flight bank indicator 7 Total energy variometer of range 10 kn 8 Total energy compensator 9 Compensating vessel 10 Electric turn and bank indicator 11 Tran...

Page 159: ...nt 1 Battery 2 3 4 5 6 Other equipment 1 I pilot safety harness 2 II pilot safety harness 3 Front tow release 4 CG tow release 5 Battery in vertical stabilizer 6 7 8 9 10 11 Prepared by Date Signature...

Page 160: ...NNEXES TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 18 4 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 2 May 2017 corrected 18 2 Record of sailplane weighing and determi...

Page 161: ...ZD 54 2 Perkoz TECHNICAL SERVICE MANUAL SECTION 18 ANNEXES Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 18 5 corrected 18 3 Elevator rudder and ailerons balance record...

Page 162: ...SECTION 18 ANNEXES TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 18 6 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected...

Page 163: ...SZD 54 2 Perkoz TECHNICAL SERVICE MANUAL SECTION 18 ANNEXES Issue II April 2014 Revision Allstar PZL Glider Sp z o o Doc No 542 4 02 page 18 7 corrected...

Page 164: ...ION 18 ANNEXES TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 18 8 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected 18 4 Calculation record of sailplane without pilots...

Page 165: ...increment values mt1 mt2 mb mao with corresponding sign or use for calculations on first page of record No Description Type Mass lb Dismounted Mounted Front instrument panel mt1i mt1i 1 2 3 4 5 Mass...

Page 166: ...N 18 ANNEXES TECHNICAL SERVICE MANUAL SZD 54 2 Perkoz page 18 10 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 2 May 2017 corrected 18 5 Record of control surfaces moveme...

Page 167: ...SZD 54 2 Perkoz TECHNICAL SERVICE MANUAL SECTION 18 ANNEXES Issue II April 2014 Revision No 2 May 2017 Allstar PZL Glider Sp z o o Doc No 542 4 02 page 18 11 corrected 18 6 Glider alignment record 2...

Page 168: ...AL SERVICE MANUAL SZD 54 2 Perkoz page 18 12 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision No 2 May 2017 corrected 18 7 Measurement record for glider control systems frictio...

Page 169: ...02 page 19 1 corrected SECTION 19 SUPPLEMENTS 19 1 Introduction Section 19 contains supplements necessary for the safe and effective use of the sailplane with mounted equipment and systems not suppli...

Page 170: ...AL SERVICE MANUAL SZD 54 2 Perkoz page 19 2 Allstar PZL Glider Sp z o o Doc No 542 4 02 Issue II April 2014 Revision corrected 19 3 Supplements List of actual pages Supplement No Page Date of issue Su...

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