TOMARK Viper SD-4 RTC User manual

TOMARK, s.r.o.
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 1
00 Preceding Pages
Viper SD-4 RTC
Airplane Maintenance Manual
Doc. N°
TOM-TC-01-AMM

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 2 Issue: 11.AUG 2016
Intentionally left blank
Issue: 04.APR 2016

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 3
Amendments
Issue
Date
Revised
pages
Description
Edition 1
04.APR 2016
all
First issue
Revision 1
11.AUG 2016
3, 5, 7-17, 24,
29, 58, 66-
200
Chapter 05-50-02 and 51-60
added, editorial changes
Revision 2
15.FEB 2017
3, 104, 109,
187, 190
AD&C-DC-58-003
Dual trim design change
Revision 3
28.FEB 2017
3, 5, 10-15,
31, 132-203
AD&C-DC-58-004
Landing Light
Revision 4
25.APR 2017
3, 5, 33, 56
Exhaust silencer Standard Major
Change EASA Project No.
0010045844
Issue: 25.APR 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 4 Issue: 11.AUG 2016
List of Service Bulletins
SB No
Date
Title
Affected
Serial no.’s
AD
(EASA)
Issue: 04.APR 2016

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 5
List of Effective Pages
Page...................................................................Page date
1 .. 2 .............................................................04.APR 2016
3 ................................................................... 28.FEB 2017
4 ...................................................................04.APR 2016
5 ................................................................... 28.FEB 2017
6 ...................................................................04.APR 2016
7 .. 9 ............................................................ 11.AUG 2016
10 .. 15 ......................................................... 28.FEB 2017
16 .. 17 ........................................................ 11.AUG 2016
18 .. 23 .........................................................04.APR 2016
24 ................................................................ 11.AUG 2016
25 .. 28 .........................................................04.APR 2016
29 ................................................................ 11.AUG 2016
30 .................................................................04.APR 2016
31 ................................................................. 28.FEB 2017
32 .. 57 .........................................................04.APR 2016
33 .................................................................25.APR 2017
56 .................................................................25.APR 2017
58 ................................................................ 11.AUG 2016
59 .. 65 .........................................................04.APR 2016
66 .. 103 ...................................................... 11.AUG 2016
104 ............................................................... 15.FEB 2017
105 .. 108 .................................................... 11.AUG 2016
109 ............................................................... 15.FEB 2017
110 .. 131 .................................................... 11.AUG 2016
132 .. 203 ..................................................... 28.FEB 2017
Issue: 25.APR 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 6 Issue: 11.AUG 2016
Table of Contents
Chapter Title ...........................................................................................Page
00 Preceding Pages...................................................... 1
00-10 List of Figures ......................................................................14
01 Introduction.......................................................... 16
01-00 General ................................................................................16
01-10 Coverage..............................................................................16
01-20 Guidelines ............................................................................16
01-30 Related Publications .............................................................17
01-40 Addresses ............................................................................18
02 How to Use the Manual.......................................... 19
02-00 General ................................................................................19
02-10 Notes ...................................................................................20
02-20 Terminology and Abbreviations ............................................21
02-30 Standard Elements................................................................21
02-40 Safety...................................................................................22
03 General Description............................................... 23
03-00 General ................................................................................23
04 Limitations ........................................................... 24
04-00 General ................................................................................24
04-10 Structural Limitations and Inspection Intervals ......................24
04-20 Placards ...............................................................................25
04-30 Major Inspection...................................................................25
04-30-10 Major Inspection Airframe ............................................................. 25
Issue: 04.APR 2016

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 7
04-30-20 Major Inspection Engine Mount ..................................................... 26
04-40 Software...............................................................................27
05 Inspection and Maintenance .................................. 28
05-00 General ................................................................................28
05-10 Time Limits and Inspection Program .....................................28
05-10-01 Component Time Limits ................................................................ 29
05-20 Scheduled Maintenance ........................................................30
05-20-01 Scheduled Inspection Plan ............................................................. 30
05-20-02 Lubrication Chart .......................................................................... 49
05-20-03 Drain Holes ................................................................................... 56
05-21 Maintenance Check Flight.....................................................57
05-21-10 Performance Tests......................................................................... 58
05-21-20 System Tests ................................................................................. 59
05-21-21 Flight Controls .............................................................................. 59
05-21-22 Engine Controls............................................................................. 60
05-21-23 Other Controls .............................................................................. 60
05-21-24 Flight Instruments ......................................................................... 61
05-21-25 Avionics ........................................................................................ 61
05-21-26 System .......................................................................................... 62
05-21-27 Engine Monitoring System (EMS).................................................... 63
05-21-28 Other Instruments ......................................................................... 64
05-21-30 Flight Handling Tests .................................................................... 65
05-50 Unscheduled Maintenance ....................................................66
05-50-01 Inspection after Spin-Event ........................................................... 66
05-50-02 Aircraft Geometry Check ............................................................... 67
06 Dimensions and Areas .......................................... 70
06-00 General ................................................................................70
06-00-01 Coordinate System ........................................................................ 70
06-10 Main Data.............................................................................70
06-10-01 External Dimensions ..................................................................... 70
06-10-02 Wing ............................................................................................. 70
06-10-03 Aileron .......................................................................................... 70
06-10-04 Aileron Trim Tab ........................................................................... 71

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Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 8 Issue: 11.AUG 2016
06-10-05 Flap............................................................................................... 71
06-10-06 Horizontal Tail............................................................................... 71
06-10-07 Elevator ......................................................................................... 71
06-10-08 Elevator Trim Tab .......................................................................... 71
06-10-09 Vertical Tail ................................................................................... 71
06-10-10 Rudder .......................................................................................... 72
06-10-11 Fuel System ................................................................................... 72
06-10-12 Landing Gear................................................................................. 72
06-10-13 Propeller........................................................................................ 72
07 Lifting and Shoring................................................ 73
07-00-01 Lifting a Main Wheel ...................................................................... 73
07-00-02 Lifting the Nose Wheel................................................................... 74
07-10 Jacking .................................................................................75
07-10-01 Jacking the Aircraft Side................................................................. 75
07-10-02 Jacking the Aircraft Front............................................................... 76
08 Leveling & Weighing.............................................. 77
08-10 Weighing and Balancing........................................................77
08-20 Leveling ...............................................................................81
12 Servicing............................................................... 82
12-10 Replenishing ........................................................................82
12-10-01 Refueling/Defueling ...................................................................... 82
12-10-02 Oil Change .................................................................................... 82
12-10-03 Coolant Replacement..................................................................... 83
12-10-04 Brake Fluid Bleeding ...................................................................... 83
12-10-05 Brake Fluid Replenishing................................................................ 84
20 Standard Practices-Airframe .................................. 86
20-10-01 Bolts.............................................................................................. 86
20-10-02 Rivets ............................................................................................ 86
20-10-03 Hoses and Tubes........................................................................... 89
20-10-04 Bowden Cables .............................................................................. 90

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Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 9
21 Air Conditioning ................................................... 91
21-20 Distribution..........................................................................91
21-40 Heating ................................................................................92
24 Electrical Power .................................................... 94
24-00 General ................................................................................94
24-30 DC Generation......................................................................94
24-30-10 Generator...................................................................................... 94
24-30-20 Battery .......................................................................................... 94
24-30-30 Signaling ....................................................................................... 95
24-60 Distribution..........................................................................95
24-60-10 Electric Current Protection............................................................. 95
25 Equipment and Furnishings................................... 96
25-10 Flight Compartment .............................................................96
25-10-01 Seats ............................................................................................. 96
25-10-02 Seat Belts ...................................................................................... 96
25-10-03 Paneling ........................................................................................ 96
25-50 Baggage Compartment .........................................................97
27 Flight Controls...................................................... 98
27-00-01 Control Stick ............................................................................... 100
27-00-02 Control Rod................................................................................. 100
27-00-03 Bell Crank.................................................................................... 100
27-00-04 Bracket........................................................................................ 101
27-10 Aileron Control...................................................................102
27-10-01 Aileron ........................................................................................ 103
27-10-02 Aileron Trim................................................................................ 104
27-20 Rudder Control...................................................................104
27-20-01 Rudder ........................................................................................ 105
27-30 Elevator and Tab ................................................................107
27-30-01 Elevator....................................................................................... 108
27-30-02 Elevator Trim............................................................................... 109

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
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27-50 Flap System........................................................................110
27-50-01 Flap............................................................................................. 111
28 Fuel.................................................................... 113
28-10 Storage ..............................................................................115
28-10-01 Drain Valve.................................................................................. 115
28-20 Distribution........................................................................115
28-40 Indication...........................................................................115
31 Indication & Recording Systems ........................... 116
31-00-01 Panel ........................................................................................... 119
31-00-02 Typical Instruments ..................................................................... 119
31-00-03 Typical Switches/Circuit breakers ................................................ 120
32 Landing Gear ...................................................... 121
32-10 Main Gear...........................................................................122
32-10-01 Main Gear Leg ............................................................................. 122
32-20 Nose Gear ..........................................................................123
32-20-01 Nose Gear Strut Fairing................................................................ 123
32-20-02 Nose Wheel Fairing ...................................................................... 123
32-20-03 Wheel Fork .................................................................................. 123
32-20-04 Shock Cord Ring.......................................................................... 124
32-20-05 Steel Cable Deflection Limiter ...................................................... 127
32-40 Wheels and Brakes..............................................................127
32-40-01 Main Wheel Fairing ...................................................................... 127
32-40-02 Main Wheel.................................................................................. 128
32-40-03 Brake Cylinder ............................................................................. 129
32-40-04 Brake........................................................................................... 129
32-40-05 Brake Linings............................................................................... 130
32-40-06 Brake Disc ................................................................................... 130
32-40-07 Nose Wheel ................................................................................. 131
32-50 Steering .............................................................................131
33 Lights................................................................. 132
33-01 Position / strobe light.................................................................. 132
Issue: 28.FEB 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 11
33-02 Landing Light .............................................................................. 133
34 Navigation.......................................................... 135
51 Standard Practices Structure................................ 136
51-00-00 Access Hatches, Covers and Fairings ........................................... 136
51-00-01 Access Hatch............................................................................... 138
51-60 Control Surface Balancing...................................................139
51-70 Repair ................................................................................144
51-71 Repair of Metal Skins..........................................................144
51-71-01 Removing Damaged Skins ........................................................... 146
51-71-02 Removing Small Dents................................................................. 146
51-71-03 Stopping Cracks .......................................................................... 147
51-71-04 Repairing the Skins with Patches ................................................. 147
51-71-10 Repair of U-Profile ...................................................................... 151
51-72 Repair of Composite Parts ..................................................151
51-72-00 Parts of External Appearance....................................................... 152
51-72-01 Small damage.............................................................................. 152
51-72-02 Medium Damage ......................................................................... 154
51-72-02 Major damage ............................................................................. 156
51-72-10 Structural Parts............................................................................ 156
51-72-11 Small Damage ............................................................................. 156
51-73 Repair of Paint....................................................................157
51-73-01 Small Damage ............................................................................. 161
53 Fuselage............................................................. 163
53-00-01 Canopy........................................................................................ 164
53-00-02 Fuseage Tail Fairing .................................................................... 164
55 Stabilizers .......................................................... 165
55-00-01 Stabilizer Tip Fairings.................................................................. 165
55-10 Horizontal Stabilizer...........................................................166
55-20 Elevator..............................................................................166
55-30 Vertical Stabilizer ...............................................................167
Issue: 28.FEB 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 12 Issue: 11.AUG 2016
55-40 Rudder ...............................................................................167
57 Wing................................................................... 168
57-10 Center Wing .......................................................................169
57-10-01 Wing Root Fairing ........................................................................ 169
57-30 Wing Tips ...........................................................................170
57-30-01 Wing Tip Fairing .......................................................................... 170
57-50 Flaps ..................................................................................170
57-60 Ailerons .............................................................................170
61 Propeller............................................................. 171
61-10-01 Propeller Blade ............................................................................ 171
61-10-02 Spinner........................................................................................ 171
71 Power Plant......................................................... 172
71-00-01 Top Engine Cowling..................................................................... 172
71-00-02 Bottom Engine Cowling................................................................ 172
71-60 Air Intakes..........................................................................173
72 Engine ................................................................ 174
72-20 Inlet Section .......................................................................174
72-20-01 Carburetor Preheating ................................................................. 174
73 Engine Fuel and Control ...................................... 175
73-20 Controlling.........................................................................175
73-20-01 Throttle Lever.............................................................................. 175
73-20-02 Choke Control Knob .................................................................... 175
74 Ignition............................................................... 176
75 Air...................................................................... 177
75-20 Engine Cooling ...................................................................177
75-20-01 Coolant Thermostat..................................................................... 177
Issue: 28.FEB 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 13
75-40 Indicating...........................................................................178
75-40-01 Coolant Temperature .................................................................. 178
79 Oil ..................................................................... 179
79-10 Storage ..............................................................................179
79-10-01 Oil Tank ...................................................................................... 179
79-20 Distribution........................................................................179
79-20-01 Oil Gear Pump ............................................................................. 179
79-20-02 Oil Radiator................................................................................. 180
79-20-03 Oil Filter ...................................................................................... 180
79-20-04 Oil System Ventilation ................................................................. 180
79-20-05 Oil Temperature Sensor............................................................... 180
79-20-06 Oil Thermostat ............................................................................ 180
80 Starting .............................................................. 181
80-00-01 Starter......................................................................................... 181
90 Emergency Equipment ........................................ 182
90-10 Aircraft Emergency Parachute System (AEPS) .......................182
91 Charts ................................................................ 186
Issue: 28.FEB 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 14 Issue: 11.AUG 2016
00-10 List of Figures
Figure 1 View ................................................................................................ 23
Figure 2 Drain holes areas............................................................................. 56
Figure 3 Measuring Sections.......................................................................... 68
Figure 4 Measuring Points Identification........................................................ 69
Figure 5 Ventilation scheme diagram ............................................................ 91
Figure 6 Heating System ............................................................................... 93
Figure 7 Control system ................................................................................ 99
Figure 8 Aileron control (left side symmetrically)......................................... 102
Figure 9 Aileron .......................................................................................... 103
Figure 10 Rudder control .............................................................................. 105
Figure 11 Rudder .......................................................................................... 106
Figure 12 Elevator control ............................................................................. 107
Figure 13 Elevator ......................................................................................... 108
Figure 14 Flap system ................................................................................... 110
Figure 15 Flap............................................................................................... 111
Figure 16 Fuel system ................................................................................... 114
Figure 17 Instrument panel ........................................................................... 117
Figure 18 Landing gear ................................................................................. 121
Figure 19 Shock cord ring replacement ......................................................... 125
Figure 20 Position light removal / installation ............................................... 133
Figure 21 Landinglight removal / installation ................................................ 134
Figure 22 Zip-tie holder................................................................................ 134
Figure 23 Access hatches, covers and fairings............................................... 136
Figure 24 Rudder balancing .......................................................................... 141
Figure 25 Elevator balancing ......................................................................... 141
Figure 26 Aileron balancing .......................................................................... 142
Figure 27 Flap balancing ............................................................................... 142
Figure 28 Location of patches on the airplane skin........................................ 148
Figure 29 Repair of the punctured skin in the frame area .............................. 149
Figure 30 Repair of the punctured skin ......................................................... 150
Figure 31 Fuselage........................................................................................ 163
Figure 32 Horizontal Stabilizer ...................................................................... 166
Figure 33 Vertical stabilizer........................................................................... 167
Figure 34 Wing.............................................................................................. 169
Figure 35 AEPS.............................................................................................. 183
Figure 36 Top view on the wire routing across the airplane ........................... 186
Figure 37 Firewall view of wire routing .......................................................... 187
Issue: 28.FEB 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Issue: 11.AUG 2016 Page 15
Figure 38 Avionics instrument interconnection ............................................. 188
Figure 39 On board electric power net .......................................................... 189
Figure 40 FR Power supply for control stick and elevator/aileron trim ........... 190
Figure 41 FU3 power supply for fuel pump ................................................... 191
Figure 42 FU2 power supply for SV-EMS220 module and EMS display ........... 192
Figure 43 FU15 power supply for intercom.................................................... 193
Figure 44 FU7 power supply for Radio........................................................... 194
Figure 45 FU1 & FU9 power supply for EFIS display and transponder............. 195
Figure 46 FU5 power supply for Flaps ........................................................... 196
Figure 47 FU8 power supply for GPS ............................................................. 197
Figure 48 FUL & FU6 power supply for Strobo lights and Nav lights............... 198
Figure 49 FU10 power supply for Socket 12/1A ............................................ 199
Figure 50 FU4 power supply for Starter Power............................................... 200
Figure 51 FU4 power supply for Starter Power............................................... 201
Figure 52 Mounting rod and cup for nose gear tensioning tools.................... 202
Figure 53 Check Flight Form ......................................................................... 203
Issue: 28.FEB 2017

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter01 Introduction
Page 16 Issue: 04.APR 2016
01 Introduction
01-00 General
This Maintenance Manual provides educated maintenance staff
information necessary for servicing, maintenance and repair of the
Viper SD-4 RTC Type aircraft. It contains a detailed description of
systems including time limits for the particular components and
instructions for the performance of inspections and maintenance.
All service, maintenance, inspections, repairs and/or modifications
shall be performed by adequately qualified/licensed personnel in
accordance with the applicable continued airworthiness regulations.
For any maintenance or repair activity not addressed in this manual,
contact TOMARK s.r.o. for approved instructions.
The instructions for installation, service, repair and maintenance of
optional equipment shall be collected with this Manual.
01-10 Coverage
This manual provides servicing and maintenance information for all
Viper SD-4 RTC aircraft.
Maintenance actions that refer to a limited number of aircraft will be
designated by serial numbers of the applicable aircraft.
01-20 Guidelines
For general information on acceptable methods, techniques and
practices, if not presented here, refer to CS-STAN (CS-SR801a).
Issue: 11.AUG 2016

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 01 Introduction
Issue: 04.APR 2016 Page 17
01-30 Related Publications
NOTE The Viper SD-4 RTC is approved by a Restricted Type Certicate. The
vendor data/publications can be used only if agreed for use by
TOMARK1.
In case a type certified engine ROTAX 912 S is installed to the aircraft
the publications of Rotax remain applicable.
Maintenance Staff may use the following links to inform themselves
about existing publications but MUST NOT apply the publication
without written approval by TOMARK or the Agency/Authority:
ROTAX AIRCRAFT ENGINES
Maintenance Manual
(Line Maintenance) for ROTAX® Engine Type 912 Series;
Edition 3, Rev. 2, February 01/2015
or later revisions only if agreed for use by TOMARK
1
Operators Manual
for ROTAX® Engine Type 912 Series
Edition 3, Rev. 2, February 01/2015
or later revisions only if agreed for use by TOMARK1
http://www.flyrotax.com
NEUFORM COMPOSITE PROPELLERS
Operating Manual
NEUFORM-Adjustable Pitch Propeller all types
28-APR-11 or later revisions only if agreed for use by TOMARK1
http://www.neuform-composites.de
GALAXY GRS s.r.o.
Instruction Manual for Assembly and Use
11.09.2015 or later revisions only if agreed for use by TOMARK1
http://www.galaxysky.cz
1
Refer to publications on TOMARK website (hhtp://www.vipersd4.com)
Issue: 11.AUG 2016

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 01 Introduction
Page 18 Issue: 04.APR 2016
01-40 Addresses
Contact:
Company
Address
TOMARK, s.r.o.
TOMARK, s.r.o., Aero division
Strojnícka č.5, 080 01 Prešov
Slovak republic
[e-mail]
ROTAX AIRCRAFT ENGINES
Refer to Rotax Service network

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter02 How to Use the Manual
Issue: 04.APR 2016 Page 19
02 How to Use the Manual
02-00 General
The format and contents of this manual have been prepared in
accordance with the GENERAL AVIATION MANUFACTURERS
ASSOCIATION (GAMA) Specification No. 2.
The content of this manual is organized in three levels:
Group
System/Chapter
Subsystem (if needed)
Group
Groups used in this manual are:
Group
Chapters
Definition / Remark
General
01 & 02
General information
Aircraft
03 thru 20
Complete operational unit,
limitations
Airframe systems
24 thru 34
All airframe systems except
power plant
Structures
51 thru 57
All aircraft main structures
Propeller
61
Propeller information
Power Plant
71 thru 80
Power plant information
Miscellaneous
90 & 91
Emergency equipment, Charts
Supplementary information
To be collected
in Appendix
Forms, Advanced maintenance
instructions, Service bulletins
etc.
System/Chapter
Systems are arranged numerically per GAMA Specification 2 (ATA 100)
recommended number assignment. The first two numbers indicate
the chapter or system; the second two indicate the sub-system or
section (for example Chapter 02-10).

TOMARK, s.r.o.
Airplane Maintenance Manual
Chapter 02 How to Use the Manual
Page 20 Issue: 04.APR 2016
When a subsystem is further divided into units, a third element is
added to the number sequence, e.g. 53-20-01
The table of content lists only those chapter numbers which are used
in this supplement.
02-10 Notes
Notes and safety notes in this handbook are marked by the words
NOTE, NOTICE, CAUTION, WARNING or DANGER in the left margin
column. The text of the note or safety note is printed in bold. See the
following definitions:
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to physical injury.
NOTE represents a remarkable hint.