TOMARK, s.r.o.
Airplane Maintenance Manual
00 Preceding Pages
Viper SD-4 RTC
Airplane Maintenance Manual
Doc. N°
TOM-TC-01-AMM
Issue: 04.APR 2016 Page 1
TOMARK, s.r.o.
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Issue: 04.APR 2016
Airplane Maintenance Manual
Chapter 00 Preceding Pages
Page 2 Issue: 11.AUG 2016
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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
Airplane Maintenance Manual
Amendments
Issue: 11.AUG 2016 Page 3
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TOMARK, s.r.o.
SB No
Date
Title
Affected
Serial no.’s
AD
(EASA)
Issue: 04.APR 2016
Airplane Maintenance Manual
List of Service Bulletins
Chapter 00 Preceding Pages
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Issue: 25.APR 2017
Airplane Maintenance Manual
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
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Issue: 04.APR 2016
Airplane Maintenance Manual
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
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Airplane Maintenance Manual
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
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
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
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Airplane Maintenance Manual
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
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Airplane Maintenance Manual
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
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Airplane Maintenance Manual
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
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Airplane Maintenance Manual
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
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Issue: 28.FEB 2017
Airplane Maintenance Manual
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
Chapter 00 Preceding Pages
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Issue: 28.FEB 2017
Airplane Maintenance Manual
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: 11.AUG 2016 Page 15
Chapter 00 Preceding Pages
TOMARK, s.r.o.
Issue: 11.AUG 2016
Airplane Maintenance Manual
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).
Chapter01 Introduction
Page 16 Issue: 04.APR 2016
TOMARK, s.r.o.
1
Issue: 11.AUG 2016
Airplane Maintenance Manual
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 TOMARK1
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
Refer to publications on TOMARK website (hhtp://www.vipersd4.com)
Issue: 04.APR 2016 Page 17
Chapter 01 Introduction
TOMARK, s.r.o.
Company
Address
TOMARK, s.r.o.
TOMARK, s.r.o., Aero division
Strojnícka č.5, 080 01 Prešov
Slovak republic
sales@tomarkaero.com
ROTAX AIRCRAFT ENGINES
Refer to Rotax Service network
Airplane Maintenance Manual
01-40 Addresses
Contact:
Chapter 01 Introduction
Page 18 Issue: 04.APR 2016
TOMARK, s.r.o.
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.
Airplane Maintenance Manual
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:
Issue: 04.APR 2016 Page 19
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).
Chapter02 How to Use the Manual
TOMARK, s.r.o.
Airplane Maintenance Manual
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.
Chapter 02 How to Use the Manual
Page 20 Issue: 04.APR 2016
TOMARK, s.r.o.
Term
Meaning
AHARS
Airborne Heading-Attitude Reference System
AFM
Airplane Flight Manual
AOA
Angle Of Attack
ATC
Air Traffic Control
CG
Center of gravity
EFIS
Electronic Flight Instrument System
EGT
Exhaust Gas Temperature
EMS
Engine Monitoring System
LH
Left Hand
LSA
Light Sport Aircraft
MFD
Multifunction-Display
RH
Right Hand
TC
Type Certificate
Airplane Maintenance Manual
02-20 Terminology and Abbreviations
02-30 Standard Elements
Text Elements
The following text elements are generally used within this manual:
Normal text
Itemization
▶ Instructions
▶ Instructions within a safety note
Head Lines
Head Lines
(when referenced)
Issue: 04.APR 2016 Page 21
Chapter 02 How to Use the Manual
TOMARK, s.r.o.
Airplane Maintenance Manual
02-40 Safety
▶ Do not begin any work before completely having read and understood
the contents of this manual and related instructions.
▶ Wear ventilated protective clothing, protective goggles, chemical
resistant gloves and respiratory mask when working with solvents or
in dusty conditions.
▶ Use protective goggles, in particular when machining some metal and
laminate parts.
▶ Wear safety gloves to protect yourself against high temperatures.
▶ Observe and follow the instructions of related products data and
safety sheets.
Chapter 02 How to Use the Manual
Page 22 Issue: 04.APR 2016
03 General Description
03-00 General
The Viper SD-4 RTC is a
low-wing,
aerodynamically controlled,
single-engine,
two-seat with side-by-side configuration,
fixed tricycle landing gear with steerable nose wheel,
all-metal
TOMARK, s.r.o.
Airplane Maintenance Manual
airplane.
Figure 1 View
Chapter03 General Description
Issue: 04.APR 2016 Page 23
TOMARK, s.r.o.
Rev. No
Description
EASA Approval
Number and date
1st Edition
Initial TC
EASA.A.606/22.MAR 2016
Revision 1
Sentence added
Issue: 11.AUG 2016
Airplane Maintenance Manual
04 Limitations
This Chapter is approved by the EASA.
04-00 General
This Chapter sets out mandatory replacement and inspection intervals
as well as other airworthiness limitations to be observed by
maintenance personnel for the Viper SD-4 RTC. Compliance with the
specified times and intervals is mandatory for maintaining the
airworthiness of the aircraft.
Other airworthiness limitations, such as operational limitations, e.g.
speeds, temperatures, pressures, fuel and oil grades, required
placards etc. are given in the approved airplane flight manual TOMTC-01-AFM.
For further manufacturer recommended time limits, maintenance
checks and inspections, refer to Chapter 05 “Time limits/Maintenance
checks”.
The aircraft must be released to service by certifying staff after any
rigging and de-rigging.
04-10 Structural Limitations and Inspection Intervals
The airframe of the Viper SD-4 RTC is limited to 6000h, the engine
mount to 4000h.
In addition, the airframe must undergo a major airframe inspection
according to 04-30 at 2000h/10year (whichever comes first) intervals
both for the airframe and the engine.
Chapter 04 Limitations
Page 24 Issue: 04.APR 2016
TOMARK, s.r.o.
Component
Relevant P/N
Wing main spar
SD4-A-2-021-N-1
Wing aft spar
SD4-A-2-222-P-3; SD4-A-2-223-N-3
Main fuselage cross beam
SD4-A-1-075-N-1
Aft fuselage cross beam
SD4-A-1-236-N-3
Aft spar attachment
SD4-A-1-294-L-7; SD4-A-1-295-L-7;
SD4-A-1-295-P-7; SD4-A-1-294-P-7;
SD4-A-1-244-N-3
Horizontal stabilizer spar
SD4-A-3-031-N-3
Horizontal stabilizer
interface
SD4-A-1-156-N-3; SD4-A-1-157-N-
3
Elevator torsion bracket
SD4-A-3-007-N-2
Vertical stabilizer spar
SD4-A-4-024-N-3; SD4-A-4-998-N-
1
Vertical stabilizer
interface
SD4-A-1-071-N-1
Brackets adjacent to
engine mount
SD4-A-1-993-N-1; SD4-A-1-500-N-
3;
SD4-A-1-509-L-7; SD4-A-1-509-P-7
Airplane Maintenance Manual
04-20 Placards
For Markings and Placards refer to Viper SD-4 RTC Aircraft Flight
Manual, Section 2, Document N°: TOM-TC-01-AFM.
04-30 Major Inspection
04-30-10 Major Inspection Airframe
The major airframe inspection program is not defined at time of print.
Upon reaching 2000hrs contact TOMARK.
Primarily addressed components are:
Issue: 04.APR 2016 Page 25
Chapter 04 Limitations
TOMARK, s.r.o.
Major Inspection engine mount
2000h
Preparatory Activities
Remove engine (recommended)
○
Clean the engine mount thoroughly
○
Inspection
Visually inspect all engine mount struts for straightness using appropriate
straight ruler lengths.
○
Check torque of all attachment bolts.
○
At locations where bolt torque is below the specified values: remove bolt
and inspect for sights of wear or overload. Discharge the respective (stop)
nuts.
If a bent bolt is found the engine mount must be removed from the
airframe to further inspect the respective bearings on airframe and engine
mount side.
Report such condition to TOMARK.
○
Visual inspect entire top coat paint of engine mount for scratches and
cracks.
○
Where top coat cracks are found remove top coat in the affected area and
min 10mm further.
○
Perform dye penetrant check at all welding nodes and all identified top
coat crack locations.
○
In case of doubt remove top coat at entire node.
○
If cracks are found report to TOMARK before proceeding
○
Airplane Maintenance Manual
04-30-20 Major Inspection Engine Mount
Relevant P/N Engine mount SD4-A-6-021-N-2
The inspection is best performed with the engine removed, which
however is not mandatory.
The inspection is required to be performed each 2000h, but
recommended to be performed whenever the engine is removed from
the airframe.
Chapter 04 Limitations
Page 26 Issue: 04.APR 2016
TOMARK, s.r.o.
Major Inspection engine mount
2000h
Finish
Refinish top coat at weld nodes as required. Touch up top coat at all other
identified scratches
○
Reinstall engine (if removed)
○
Make appropriate airplane log book entry for release to further service
○
Function
Unit
Software revision
(approved at time of print)
MFD/EMS
configuration
Dynon
Skyview System
SV-D1000, version 13.0
Airplane Maintenance Manual
04-40 Software
Only Software delivered with the airplane, or as mandated by
respective Service Bulletins are approved to be used in the Viper SD-4
RTC. This addresses:
Issue: 04.APR 2016 Page 27
Chapter 04 Limitations
TOMARK, s.r.o.
Airplane Maintenance Manual
05 Inspection and Maintenance
05-00 General
This chapter contains charts, tables and checklists for time limits,
scheduled and unscheduled maintenance, to enable licensed
personnel to carry out correct inspections on the Viper SD-4 RTC
aircraft. The periodic inspections and checks described and the
related intervals are minimum required for maintaining the aircraft in
airworthy condition.
Specific operation and specific operation environments might require
shortening the intervals.
The regulating airworthiness authority must approve any increase of
interval time.
NOTE The regulatory authority might require specific (additional) inspection
or calibration items as well as replacement/overhaul intervals not
described in this manual. It is the responsibility of the operator and
maintenance personnel to adhere to national regulations.
05-10 Time Limits and Inspection Program
The Viper SD-4 RTC aircraft scheduled inspection and maintenance
program comprises:
Non repetitive aircraft inspection at 25 hours after delivery of the
aircraft or installation of a new, rebuilt or overhauled engine,
including a break-in inspection and maintenance of the power plant
corresponding to the 100 hours/annual inspection.
Recommended repetitive 50 hour inspection mainly covering power
plant, and fuel system (firewall forward).
Mandatory repetitive 100 hour inspection or annual inspection,
whichever comes first, which includes the coverage of the 50 hour
inspection plus the inspection of the aircraft controls, structure
landing gear and the fuel system aft of firewall.
Chapter 05 Inspection and Maintenance
Page 28 Issue: 04.APR 2016
TOMARK, s.r.o.
Component
Interval
Propeller Neuform
1500 h
Rotax 912 S / ULS Engine
2000 h / 15 years
(refer to latest ROTAX
documentation applicable to
the actual SN of the engine)
Component
Interval
ELT Batteries
5 years
Dynon SkyView Batteries
Depending on annual test
result
Engine mount
4000h
Fuel, oil and coolant hoses
5 years
Issue: 11.AUG 2016
Airplane Maintenance Manual
Unless stated otherwise the inspection methods follow standard
practice and are mainly visual. However specific attention shall be
paid to the elements listed in section 04-30-10. In case of doubt
perform dye penetrant inspections at the welding connections and
highly stressed areas as indicated in the inspection list.
05-10-01 Component Time Limits
Time Between Overhaul
Time Between Replacement
Issue: 04.APR 2016 Page 29
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection Report
Type
Viper SD-4
Model
Viper SD-4 RTC
Serial Number
Registration
Owner
Date
Type of Inspection
Airframe time (logbook)
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Preparatory Activities
Review of aircraft logbook
○ ○ ○1
Carry out a Daily Inspection according the flight manual.
○ ○ ○
1
Flight check according to
05-21 Maintenance Check Flight
,
review results
○ ○
1
Start up engine in accordance with AFM
○ ○ ○1
Check all engine related instrumentation and fuel quantity.
○ ○ ○1
Check voltage indication.
○ ○ ○1
Check function of exterior lights as installed.
○ ○ ○1
Shut down in accordance with AFM.
○ ○ ○1
Check that all applicable Service Bulletins are complied with.
○ ○ ○
1
Check that all applicable Airworthiness Directives are
complied with.
○ ○ ○
1
1
Airplane Maintenance Manual
05-20 Scheduled Maintenance
05-20-01 Scheduled Inspection Plan
First 25 hours of operation for new or overhauled engine
Chapter 05 Inspection and Maintenance
Page 30 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Clean exterior of aircraft as required, pay attention to any
unusual surface condition.
○ ○ ○
1
Vacuum clean aircraft interior as required.
○ ○ ○
1
Ensure the entire aircraft is clean.
○ ○ ○
1
Remove top and bottom engine cowling
○ ○ ○
1
Clean and inspect cowling structures for cracks, dent and
other damage, security of cowl fasteners.
○ ○ ○1
Check hinge and locking mechanism of oil access hatch for
proper operation.
○ ○ ○
1
Inspect cowling internal coating for deterioration and signs of
overheat.
○ ○ ○
1
Inspect Landing Light attachment
○ ○ ○
1
Inspect Landing Light wiring attachment
○ ○ ○
1
Engine Installation
Take precautions against accidental starting or firing of the
engine by removing ignition leads.
○ ○ ○1
Perform engine inspection, oil change etc. according to
ROTAX 912 Line Maintenance and Operators Manual, Chapter
05-20-00.
○ ○ ○1
Air Induction
Visually check the condition, mounting and cleanleness of the
air filters at the inlet into the carburetors or the airbox. Clean
the air filters, if necessary.
○ ○ ○1
Visually check the condition of the intake manifold.
○ ○ ○1
Visually check the condition of the carburetors and control
elements.
○ ○ ○1
1
Issue: 28.FEB 2017
Airplane Maintenance Manual
First 25 hours of operation for new or overhauled engine
Issue: 04.APR 2016 Page 31
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Oil System
Check oil thermostat for proper attachment. Inspect for
leakage.
○ ○ ○1
Inspect oil breather line for proper routing, internal
accumulation of oil/water emulation, and clogging. Clean as
required.
○ ○ ○1
Visually check the condition of the radiator mounting brackets
for cracks.
○ ○ ○1
Inspect cooling fins for dirt and damage.
○ ○ ○
1
Visually check the condition of the hoses, their attachment,
the tightening of their fittings and the tightness of the oil
system. If necessary, tighten the hose connection fittings or
replace damaged hoses.
○ ○ ○1
Visually check the condition and attachment of the oil tank.
○ ○
Visually check the condition, attachment and tightness of the
oil radiator.
○ ○
Coolant System
Visually check the condition of the radiator mounting brackets
for cracks.
○ ○ ○1
Check coolant thermostat for proper attachment. Inspect for
leakage.
○ ○ ○1
Visually check the condition, integrity and attachment of the
hoses and the tightness of the cooling system. Tighten the
hose fittings or replace the hoses, if necessary.
○ ○ ○1
Inspect cooling fins for dirt and damage.
○ ○ ○1
Inspect coolant radiator for leaks and proper installation.
○ ○ ○1
1
Airplane Maintenance Manual
First 25 hours of operation for new or overhauled engine
Chapter 05 Inspection and Maintenance
Page 32 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Visually check the condition and attachment of the expansion
tank on the firewall.
○ ○
Fuel System
Visually check the condition of the fuel hoses, connection of
the fuel hoses, their attachment and tightening. Replace
mechanically damaged, cracked or hardened hoses.
○ ○ ○1
Visually check the fuel filter for dirt. Replace the fuel filter, if
it is clogged.
○ ○ ○1
Exhaust System
Visually inspect flanges and stack-pipes.
(Exhaust stack attachment studs & nuts are prone to loss of
torque due to vibration and thermal expansion.)
○ ○ ○1
Check EGT sensors for proper installation.
○ ○ ○1
Visually inspect muffler and additional muffler for cracks,
leakage and security of attachment.
○ ○ ○1
Engine Controls
Check throttle control for proper attachment, full travel,
freedom and smoothness of movement.
○ ○ ○
1
Clean and lubricate Bowden cable. Refer to Luprication plan.
500h/
5 Years
Inspect all wiring connected to the engine, regulators and
accessories for attachment, leads, chafing etc.
○ ○ ○1
Inspect all firewall-mounted items for security of attachment.
○ ○ ○1
Check battery for general condition, recharge as required.
Apply a thin layer of grease to the battery connections.
○ ○ ○1
Inspect battery cables for signs of corrosion or cracks. Check
cable routing and attachment.
○ ○ ○1
1
Issue: 25.APR 2017
Airplane Maintenance Manual
First 25 hours of operation for new or overhauled engine
Issue: 04.APR 2016 Page 33
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Inspect battery isolation provisions.
○ ○ ○1
Cabin Heat System
Inspect hoses for attachment, leaks and wear.
○ ○
Inspect air scoop at radiator for cleanness
○ ○
Inspect save closure of cabin air nozzles and vents
○ ○
Inspect heat exchanger on exhaust for cracks
○ ○
Engine Mount
Inspect engine mount attaching bolts at the firewall. Check
torque on all attachment points, re-torque as required.
○ ○ ○1
Inspect shock mount rubber elements (vibration isolators) for
condition.
○ ○ ○1
Check engine to shock mount attaching bolts, castle nuts and
cotter pins.
○ ○ ○1
Inspect engine mount structure for cracks and damage.
Pay specific attention to weld connections. In case of doubt
consider dye penetrant inspection.
○ ○
Visually check the firewall for cracks and corrosion, in
particular in the places of all the engine mount attachment
points.
○
Unscrew and visually check the condition of the bolts
attaching the engine to the engine mount.
1000h
Perform Major engine mount inspection per
04-30-20.
2000h
Propeller
Remove spinner.
○ ○ ○1
Inspect spinner for cracks and fractures.
○ ○
Inspect propeller mounting bolts. Re-torque mounting bolts.
○ ○ ○1
1
Airplane Maintenance Manual
First 25 hours of operation for new or overhauled engine
Chapter 05 Inspection and Maintenance
Page 34 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Inspect propeller mounting for security of installation.
○ ○
Inspect propeller blades for cracks, dents, nicks, scratches,
erosion or other damage.
○ ○
The propeller must have a major overhaul by NEUFORM.
1500h
Inspect propeller blade mounting for wear and play (no play
allowed at blade tip in any direction).
A little angular play in the gear is normal (1-2 mm at blade
tip). To make sure that no additional play is present in the
blade retention manually counteract play detection force at
the spinner or another blade to eliminate the gear influence.
○ ○
Measure actual propeller blade angles 22° (+/- 0.5°) at
425 mm from root of the blade (gaugeable secant angle).
○ ○
Reinstall spinner. Check for proper attachment.
○ ○ ○1
Finish
Inspect entire engine compartment for foreign objects, loose
connections of earlier work, correct application of safety wire
and cotter pins at all locations where work was executed.
○ ○ ○1
Landing Gear & Brakes
Nose Landing Gear
Check nose gear for condition and attachment. Check the play
of the nose landing gear strut, the wear of centering blocks,
the tightening of the connection elements and their locking.
○ ○
Visually check the shock cord rings for cracks, rubs and
excessive wear. Replace the shock cord rings, if it is damaged.
○ ○
Visually check the steel cable deflection limiter and condition
of its rubber protection. Replace on condition.
○
1
Airplane Maintenance Manual
First 25 hours of operation for new or overhauled engine
Issue: 04.APR 2016 Page 35
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Inspect nose gear steering push-pull rods and their
attachment. Lubricate rod ends as per Section
05-20-02
Lubrication Chart
.
○
Demount the nose gear strut fairing.
○
Visually check the nose gear strut fairing for cracks and other
damage
○
Loosen nose wheel fairing and push upwords.
○
Visually check the nose wheel fairing for cracks and other
damage
○
Inspect nose gear fork for deformation, cracks in welding
seams or due to material fatigue or stress.
○
Check the condition of the static discharge wire.
○
Nose Landing Gear Wheels and Tires
Check the attachment of the wheel disk and its locking.
○ ○
Inspect tires for cracks, cuts and condition.
○ ○
Check the condition of the valve at the opening of the rim.
○
Inspect slip marks for proper alignment.
○ ○
Visually check the wheel disk for cracks and deformities.
○
Check the play in the bearings and the free turning of the
wheels.
○
Finish
Reinstall the fairings after the inspection of the nose landing
gear is done.
○
Check tire pressure:
Nose Landing Gear 1.2 bar
○ ○
Main Landing Gear
Visually check the condition of the landing gear legs for
cracks and signs of delamination.
○ ○
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 36 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Check the tightening of the bolts and their locking.
○ ○
Check the attachment of the legs to the aeroplane’s fuselage
for possible play by moving a leg forward and backward, up
and down. If play is found, tighten the leg attachment bolts.
○
Main Landing Gear Wheels and Tires
Demount the main wheel fairings.
○
Visually check the main wheel fairings for cracks and other
damage
○
Inspect tires for cracks, cuts and condition.
○ ○
Check the attachment of the wheel disks and their locking.
○ ○
Visually check the wheel disks for cracks and deformities.
○
Check the condition of the valve at the opening of the rim.
○
Inspect slip marks for proper alignment.
○ ○
Check the play in the bearings and the free turning of the
wheels.
○
Brakes
Inspect brake cylinder in the cockpit for leakage, damage and
attachment.
○ ○
Inspect brake disc and linings for wear and cracks, replace as
required.
○ ○
Inspect wheel brake caliper and pistons for damage wear,
leakage and cleanliness.
○ ○
Check brake lines and hoses for proper routing and
attachment.
○ ○
Check brake filling state according AFM, refill as required.
○
Replace brake fluid.
200h/
2 years
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 37
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Finish
Check park brake action. (brake lock must allow no slip of
aircraft at 100% max power)
○ ○
Reinstall the main wheel fairings after the inspection of the
main landing gear is done.
○
Check tire pressure:
Main Landing Gear 2.2 bar
○ ○
Wings
Visually check the condition of the wing skin and the
condition of the riveting. No deformations, cracks, or
loosened rivets are allowed.
○ ○
Check the condition and attachment of the wing tip and
navigation lights.
○
Inspect wing internal for accumulation of water and/or
moisture.
○
Demount the inspection hatches and check the condition of
the control pull-push rods.
Check for torque of joints, jamming, excessive play and
excessive wear. Correct on condition.
○
Visually check the condition of the rivet joints and sealant of
the fuel tanks for tightness.
○
Check the connection, integrity, tightening and locking of the
fuel hoses. Visually check the area around the fuel meters and
the fuel hoses for tightness of the fuel system.
○
Check the connection of the fuel meters and the condition of
the electric cables.
○
Perform Major inspection according to
04-30-10.
2000h/
15years
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 38 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Ailerons
Visually check the condition of the ailerons. The condition of
the skin and riveting.
○ ○
Check the free movement of the ailerons.
○ ○
Check the torque and locking of the aileron push-pull control
rods. Replace protective teflon tape at Aileron control stops.
○ ○
Check the attachment of the trim tab for play and other
damage.
○ ○
Demount the inspection hatch and check the attachment of
the aileron trim servo and the locking of the trim tab control
push-pull rod.
○ ○
Check the electric cables of the trim tab control for damage.
○ ○
Check the piano hinges (attachment of the ailerons) for play
and other damage.
○
Flaps
Completely extend the flaps and visually check the overall
condition of the skin and riveting.
○ ○
Check the flap attachment hinges.
○ ○
Check the play of the flaps.
○ ○
Check the torque and locking of the flap control push-pull
rods.
○ ○
Demount the inspection hatches and check the flap control
push-pull rods. Check for torque of joints, jamming,
excessive play and excessive wear. Correct on condition.
○ ○
Pitot-static system
Check the condition and attachment of the air pressure
sensor.
○ ○
Check the condition and attachment of the piping of the
Pitot-static system.
○
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 39
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Wing attachment
Demount the wing root fairings.
○ ○
Visually check the condition of the wing root fairings for
cracks and other damage. Repair or replace, if necessary.
○ ○
Check the torque and locking of the main wing spar bolts and
of the rear spar bolt with a torque wrench.
○ ○
Visually inspect all the connections at wing attachments.
○ ○
Check the attachment of the wings for play by moving the
wing forward and back, up and down.
○
Lubricate according to the lubrication plan Section
05-20-02
Lubrication Chart
.
○ ○
Reinstall the wing root fairings only after the completion of
the inspection.
○ ○
Fuselage
Visually check the skin and the riveting. No deformities,
cracks or loosened rivets are allowed.
○ ○
Visually check the rivets near the main landing gear legs.
○
Check the condition and the attachment of the antennas,
beacons and other external installations
○ ○
Perform Major inspection according to
04-30-10.
2000h/
15years
Canopy
Visually check the canopy for cracks, scratches and other
damage. In case of crack detection contact TOMARK Aero for
instructions.
○ ○
Check the condition of all attachments of the canopy.
○ ○
Check the condition and movement of the canopy windows.
○
Check the functioning of the gas springs.
○
Check the condition of the canopy sealing.
○
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 40 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Horizontal stabilizer
Demount the fuselage tail fairing. Reinstall the fairing only
after the completion of the inspection.
○ ○
Visually check the fuselage tail fairing for cracks and other
damage. Repair or replace, if necessary.
○ ○
Visually check the horizontal stabiliser. The skin and the
riveting. Deformations, cracks, scratches or loosened rivets
are not allowed.
○ ○
Check the condition of the hinges of the horizontal stabiliser.
The torque of the connecting bolts and their locking.
○ ○
Check the condition and attachment of the stabilizer tip
fairing.
○
Check the attachment of the horizontal stabiliser by moving
the stabiliser forward and backward, up and down.
○
Check the attachment elements of the stabiliser, the torque
and locking of the bolts.
○
Elevator
Visually check the condition, skin and riveting of the elevator.
Deformations, cracks, scratches and loosened rivets are not
allowed. Pay specific attention to weld seams and rivet
connections on the elevator torsion tube bracket.
○ ○
Check the elevator for free movement.
○ ○
Visually check the hinge of the elevator for corrosion, cracks,
bolt locking and control connections.
○
○
Check the attachment of the elevator trim tab for play and
other damage.
○
Remove the inspection hatch and check the attachment of the
servo and the locking of the pitch trim tab pull-push rod.
○
Check the electric wiring of the trim control for damage.
○
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 41
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Lubricate according to the lubrication plan
05-20-02
Lubrication Chart
.
○
Check the connection of the elevator controls.
500h/
5 years
Vertical Stabilizer
Visually check the condition of the vertical stabiliser.
Deformations, cracks, scratches and loosened rivets are not
allowed.
○ ○
Check the condition and attachment of the stabilizer tip
fairing.
○ ○
Check the condition of the rudder hinges.
○ ○
Check the elements of the attachment of the vertical
stabiliser, the torque and locking of the connecting elements.
Check for other possible damage.
○
Rudder
Visually check the condition of the rudder, check the hinges.
Deformations, cracks, scratches and loosened rivets are not
allowed.
○ ○
Visually check the hinge for corrosion, the torque and locking
of the pins and connections of the rudder control.
○ ○
Lubricate according to the lubrication plan
05-20-02
Lubrication Chart
.
○ ○
Check the positioning of the rudder and maximum deflections
(rudder stops).
500h/
5 years
Check the connection of the rudder.
500h/
5 years
Cockpit
Seats and harness
Demount the seats and the panelling of the cockpit (mount
back after the inspection has been completed).
○
○
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 42 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Visually check the upholstering of the seats and of the cockpit
area.
○
○
Check the condition of the seats for cracks in the structure.
○
Visually check the condition and anchoring of the harness.
○
○
Front and aft fuselage cross spar
Visually check the condition of the wing box. Deformations,
cracks, loosened rivets and other damage are not allowed. Pay
specific attention to wing spar attachment areas.
○
Visually check the condition of the aft fuselage spars.
Deformations, cracks, loosened rivets and other damage are
not allowed. Pay specific attention to wing spar attachment
areas.
○
Control systems
Flap Actuation System
Check for condition and proper, smooth operation through
full travel. Check for free movement.
○ ○
Lubricate bearings as required
05-20-02 Lubrication Chart
.
○
Visually check the attachment, torque and locking of the
electric flap drive in fuselage.
○
Check condition of the flap control transmission in wing and
fuselage. Check push rods for condition and security. No gap
to the rod ends. Check rivets for security of attachment.
○
Check deflections. Nominal values:
15⁰ ± 2⁰
30⁰ ± 2⁰
40⁰ ± 2⁰
500h/
5 years
Visually check in fuselage the rivets connecting the torsion
tube with the fitting for the wing quick connect. (3 rivets each
left and right must be tight and no cracks in tube - use mirror
and operate flap)
500h/
5 years
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 43
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Aileron and Elevator Control
Check for condition and proper, smooth operation through
full travel. Check for free movement.
○ ○
Check control system push rods and torsion tube inside the
fuselage for condition, security, and operation through full
travel. Check rivets for security of attachment.
○
Check brackets for condition and security of attachment to
surrounding structure.
○
Check condition and security of travel stops.
Replace aileron travel stop Teflon strips on condition.
○
Check push rods inside the wing for condition and security.
○
Visually check control stick weld seams and for tube
deformation.
500h/
5 years
Check aileron deflections. Nominal values:
Up +27⁰ ± 1⁰
Down -16⁰ ± 1⁰
500h/
5 years
Check elevator deflections. Nominal values:
Up +25⁰ ± 1⁰
Down -20⁰ ± 1⁰
500h/
5 years
Elevator and Aileron Trim Tab System
Check for condition, security, free movement and operation.
○ ○
Check torque of counternuts on trim pushrods (elevator and
aileron drive)
○
Check switch positions in relation to the travel direction.
○
Check elevator trim deflections with elevator neutral. Nominal
values:
Up +21⁰ ± 2⁰
Down -33⁰ ± 2⁰
500h/
5 years
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 44 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Check aileron trim deflections with aileron neutral. Nominal
values:
Up +28⁰ ± 2⁰
Down -28⁰ ± 2⁰
500h/
5 years
Rudder Control System
Check for condition and proper, smooth operation through
full travel. Check for free movement.
○ ○
Check rudder travel stops for signs of overload.
○
Inspect Bowden cables for wear, security, condition and
operation through full travel.
○
Check Bowden cable counter brackets for condition and
secure fastening of adjustment.
○
Check cable tension.
○
Check rudder pedals for general condition and proper
attachment. Visually inspect for cracks and deformation.
○
Check rudder deflections. Nominal values:
Left +30⁰ ± 1⁰
Right -30⁰ ± 1⁰
500h/
5 years
Fuel System (excluding firewall forward)
Turn on the fuel pump (do not start the engine). Open shutoff valve and check all fuel system connections downstream of
the electric fuel pump for leaks.
200h/
2 Years
Check fuel pressure indication reads 0.17-0.5bar (fuel pump
on).
If values are outside 0.17-0.5bar, inspect fuel lines for
clogging and kinks, and replace fuel filter.
200h/
2 Years
Check fuel selector valve function by closing while fuel pumps
are running. Check fuel pressure indication drop, re-open fuel
selector valve and check fuel pressure regain.
200h/
2 Years
Fuel Tank
Inspect fuel tank for evidence of leakage and/or damage.
○
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 45
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Check fuel cap for condition and proper operation.
○
Drain fuel at fuel tank bottom.
○
Remove drain valve and inspect for sediment
200h/
2 Years
Fuel Lines, Hoses and Elements
Inspect fuel lines and hoses for damage, leakage and proper
routing.
○
Visually inspect fuel selector valve for leakage.
○ ○
When refilling system after complete drain (aircraft in level
attitude):
Check indication and low level warning operation.
Indicator must not start indication of usable fuel when total
fuel quantity in system is below published unusable quantity
of 5 Liter per side. Low level warning must trigger at steady
quantity of 10 Liter per side.
500h/
5 years
Instruments
Check instruments for condition, security and proper
markings. (Instrument dials or markings may not be
excessively faded out due to sunlight.)
○
Check instrument lines and wiring for condition, proper
routing, and security.
○
Check Pitot-static system for condition, proper installation
and security.
○
Check Pitot-static system moisture traps, clean as required.
○
Perform Pitot-static system leak test:
Pitot: pressurize to 100 KIAS, allowable drop 5 knots/min
Static: evacuate to 1000 ft., allowable drop 100 ft./min.
Note: allow vertical speed indicator (on EFIS) to stabilize
before taking measurement. Most likely points of leakage are
the instruments themselves and hose connections.
200h/
2 Years
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 46 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Avionics
Inspect avionics units and related antennas for security of
installation and condition.
○
Inspect cables and connectors for attachment.
○
Inspect microphone and jacks for cleanliness security and
evidence of damage.
○
Inspect ELT mounting attachment.
○
Conduct
Magnetic Heading Calibration
of AHARS as per
DYNON AVIONICS SkyView
System Installation Guide
latest
Revision.
○1
Follow the
Instructions of Continued Airworthiness
as per
DYNON AVIONICS SkyView
System Installation Guide
latest
Revision.
○
Check ELT for condition and exp. Date of battery, replace
battery if needed.
○
Perform radio and transponder check
○1
Magnetic Compass
Check magnetic compass for security and cleanliness. Inspect
for leakage and evidence of damage.
○ ○
Perform magnetic compass compensation.
○2
Electrical System (excluding firewall forward)
Inspect electric wiring for proper routing chafing loose or
broken wires/connectors, check attachment.
○
Inspect circuit breakers and switches for operation and
security.
○
1
2
Airplane Maintenance Manual
As mandated by local regulations
According to country-specific requirements
Issue: 04.APR 2016 Page 47
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Check navigation and strobe light for condition and proper
installation.
○
Emergency
Revise the Aircraft Emergency Parachute System.
○1
Placards (refer to pilot’s operating handbook)
Placards and Decals: Check presence, legibility and security.
Consult AFM for required placards exterior and interior.
○
Finish
Inspect all aircraft compartments for foreign objects, tools
etc.
○ ○ ○2
Reinstall (as applicable):
Aerodynamic fairings
Note: If specific work involved opening/closing of oil, coolant
or fuel system related hose connections, it is advised to
execute a short ground run without cowling to check for
leaks.
○ ○ ○
2
Check seat belt routing
○ ○ ○2
Check control system operation.
○ ○ ○2
Reattach ignition leads to spark plugs if removed. Reattach air
box hose if bottom cowling was removed.
○ ○ ○2
Ground Run
Perform engine ground run (without upper cowling) according
to ROTAX 912 Line Maintenance and Operators Manuals.
Observe the following when performing an engine test run:
○ ○ ○2
Check general conditions and power plant start behaviour
○ ○ ○2
Check pressures, temperatures, acceleration performance
○ ○ ○2
1
2
Airplane Maintenance Manual
At latest after 6 years
First 25 hours of operation for new or overhauled engine
Chapter 05 Inspection and Maintenance
Page 48 Issue: 04.APR 2016
TOMARK, s.r.o.
Scheduled Inspection
(50 h)
100 h/
annual
as
specified
Perform Full Throttle Test Check.
○ ○ ○2
Check brakes at full throttle
○ ○ ○2
Check Idle RPM (refer to ROTAX 912 Operators Manual).
○ ○ ○1
Fuel pressure within limit over complete RPM range both
pumps individual and in combination.
○ ○ ○1
Check battery and power generation.
○ ○ ○
1
Install engine cowlings
○ ○ ○1
Perform maintenance check flight according to
05-21
Maintenance Check Flight
○ ○1
Make appropriate aircraft and engine logbook entries for
scheduled power plant service.
○ ○ ○1
Ensure all Maintenance Record log-book entry’s required are
complied with before the aircraft return to service.
○ ○ ○1
File all documents e.g. inspection report, ground run report
Forms and tags in aircraft history file.
○ ○ ○1
1
Airplane Maintenance Manual
05-20-02 Lubrication Chart
Three types of lubricants are used which are recommended:
LPS1 – Non-fat lubricant
Basic characteristics: dissolve fat and oils repels oil, dust and
sediments
creates dry, thin lubricated layer quickly penetrates and removes
moisture loosens rusted and seized parts; offers short term corrosion
protection safe for all surfaces
LPS2 – Strong industrial lubricant
Basic characteristics: creates everlasting thin oil layer; usage on outer
and inner devices; increased corrosion protection; expels moisture;
First 25 hours of operation for new or overhauled engine
Issue: 04.APR 2016 Page 49
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Item
Lubricant
100 h
as
specified
Engine
Throttle control cable + spring (2x)
LPS2
○
○1
Choke control cable + spring (2x)
○
○
1
Air box revolving control joints (2x)
○
Heating shutter cable (1x)
LPS1
500 h
Air box control cable (1x)
500 h
1
Airplane Maintenance Manual
lowers the wearing out caused by friction and corrosion; loosens
rusted and seized parts safe for plastic, rubber and paint
Castrol LMX – High pressure plastic lubricant based on lithium
compounds
Basic characteristics: It guarantees long term lubricating. Appropriate
also for high temperature stressed bearings. Temperature range from
-30 °C to +150 °C; appropriate for bearings, joint mechanisms and
reduction devices; expand lifetime of lubricate mechanism, excellent
corrosion protection; non soluble in water; easy to use
NOTE Flight plastic lubricant AeroShell Grease 22 can be used as an
acceptable alternative for Castrol LMX.
First 25 hours of operation for new or overhauled engine
Chapter 05 Inspection and Maintenance
Page 50 Issue: 04.APR 2016
TOMARK, s.r.o.
Item
Lubricant
100 h
as
specified
Nose landing gear
Upper and lower „plastic“ slide bearing
Castrol
LMX
○
Arresting plastic washers (2x)
○
○1
Front rods nodes (2 nodes)
○
Flaps
Wings flaps controls (Flaps 2x 2 nodes)
Castrol LMX
500 h
Flaps hinges (2x 3 nodes)
○
Ailerons
Wings ailerons controls (2x 7 nodes)
Castrol LMX
500 h
Ailerons + Trim piano hinge (3x hinge)
LPS1
○
1
Airplane Maintenance Manual
First 25 hours of operation for new or overhauled engine
Issue: 04.APR 2016 Page 51
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Item
Lubricant
100 h
as
specified
Rudder
Rudder hinges (2 nodes)
Castrol LMX
○
Rudder lever control (2 nodes)
500 h
Bowden wire on the outlet (2x)
LPS2
○
Elevator
Elevator hinges (4 nodes)
Castrol LMX
○
Elevator lever (2 nodes)
LPS2
○
Elevator trim piano hinge (1x hinge)
LPS1
○
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 52 Issue: 04.APR 2016
TOMARK, s.r.o.
Item
Lubricant
100 h
as
specified
Aileron and elevator control
Control stick joint mechanism (6 nodes)
Castrol
LMX
500 h
Rods and lever elevator control (4 nodes)
500 h
Servo flap joint mechanism (1 nodes)
500 h
Lever joints of aileron control (2 nodes)
LPS2
500 h
Rudder control
Guidance slots in steering lever (2 nodes)
Castrol
LMX
○
Connection place of nose landing gear rods
and levers (2 nodes)
500 h
Levers joint mechanism (2 nodes)
○
Connection nodes of rudder Bowdens(2 nodes)
500 h
Rudder Bowden wire (2x)
LPS2
○
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 53
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Item
Lubricant
100 h
as
specified
Cockpit
Rotary joints of cockpit arm dumper (2x 2
nodes)
LPS2
500 h
Hinge bearings of cab canopy (2 nods)
500 h
Slide plastic bearing cab lock (2 nods)
500 h
Lock bearings and cab arms (2x 2nods)
Castrol LMX
500 h
Airplane Maintenance Manual
Chapter 05 Inspection and Maintenance
Page 54 Issue: 04.APR 2016
TOMARK, s.r.o.
Item
Lubricant
100 h
as
specified
Throttle
Connecting areas of sliding bearing
500 h
Throttle control cable (2 cables)
500 h
Airplane Maintenance Manual
Issue: 04.APR 2016 Page 55
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Issue: 25.APR 2017
Airplane Maintenance Manual
The Viper SD-4 RTC features a number of dry bearings which in
essence do not need any lubrication, if those bearings are
questionable in their status just clean and inspect. In case the bearing
shows signs of wear they need to be replaced.
The wheel bearings are life time lubricated - in case of questionable
status they need to be replaced.
05-20-03 Drain Holes
Drain holes are located in fuselage and empennage bottom and one
drain hole is located at the bottom of additional exhaust muffler.
Drain holes must be inspected regular for obstruction.
Figure 2 Drain holes areas
Chapter 05 Inspection and Maintenance
Page 56 Issue: 04.APR 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
05-21 Maintenance Check Flight
The maintenance check flight is intended to check whether the
aircraft can be released for service. Reasons for performing a
maintenance check flight can be different. Examples include restoring
to operation after the aircraft has been stored for a long period, with
yearly maintenance, or aircraft modifications. The maintenance check
flight should be performed by a pilot who has sufficient experience
with general aviation aircraft and is sufficiently familiarized with the
type. Prior to starting the maintenance check flight the ground tests
have to be completed satisfactorily and the aircraft has to be released
by authorized personnel for the maintenance check flight. The pilot
should read the relevant chapters in the airplane flight manual prior
to executing the maintenance check flight.
NOTE The pilot should be aware of the fact that due to
maintenance/modifications systems may have malfunctions which
have not been discovered in prior inspections.
The Maintenance check flight is to be conducted using the
Maintenance Check Flight Form (Figure 53). On this form all the items
to be checked are indicated. For all the relevant items a short
description is given here. The maintenance check flight is not
intended to fly a complete evaluation program but covers all the
relevant items satisfactorily to be able to decide whether or not the
aircraft can be released for further service. Start with filling in the
items on the first four rows. These parameters reflect the general
aircraft data, meteorological and flight conditions.
General
The maintenance check flight consists of three parts: performance
tests, system tests, and flight handling tests. However, some of the
system tests are best to be done on with the engine running on
ground. For the flight test, use airspace that is sufficiently clear of
other traffic so the pilot is not distracted from executing the tests. For
flight handling, the flight altitude should be sufficient for executing
the specific tests and should include a sufficiently large safety margin.
If the weather does not permit this, postpone the test but do not omit
it from the program. If during the test any indication shows a possible
Chapter 05 Inspection and Maintenance
Issue: 04.APR 2016 Page 57
TOMARK, s.r.o.
Issue: 11.AUG 2016
Airplane Maintenance Manual
malfunctioning, do not continue the test but land as soon as practical
and have the aircraft inspected.
After the maintenance check flight has been completed and the form
has completely been filled in, the authorized inspector can proceed
with the release to service procedure according to the applicable
regulations.
05-21-10 Performance Tests
The goal of the performance tests is to have a spot check of three
relevant flight conditions in the envelope. Climb, cruise, and full
throttle level flight are checked. Both flight performance and engine
performance are monitored.
Climb
Fly the aircraft at a speed 65 KIAS using a full throttle and flaps
retraced. Fly this as stationary as possible while monitoring the flight
and engine instruments. Note down the relevant values on the form.
Do not fly this test for a too short period. Allow the engine to stabilize
the oil temperature. Compare this data with the data displayed in the
airplane flight manual. The corrected flight data should correlate with
the data in the airplane flight manual. Correction procedures are
given in the flight manual.
Cruise
Fly the aircraft at a typical cruise speed of 95 KIAS. Monitor the
indicated parameters. Allow the situation to stabilize before writing
down the data. Compare this data with the data displayed in the
airplane flight manual. The corrected flight data should correlate with
the data in the airplane flight manual.
Chapter 05 Inspection and Maintenance
Page 58 Issue: 04.APR 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
Max Continues Power Level Flight
Fly the aircraft at full throttle (climb). Build up speed in moderately
into level flight and reduce RPM gradually until MCP (5500RPM) is
reached. Allow the aircraft to stabilize for some time. Fly this
maneuver as stationary as possible. Write down the requested
parameters. Compare this data with the data displayed in the airplane
flight manual. (Fly this maneuver at minimum safe altitude). The
corrected flight data should correlate with the data in the airplane
flight manual.
05-21-20 System Tests
The system tests are meant for checking the systems of the aircraft.
The systems are subdivided into 7 groups. For each group the
relevant systems are indicated on the form. Check their functionality
and indication where relevant. On the form indicate an acceptable
functionality with a “+”. A functionality which is not acceptable should
be indicated with a “-“. Use the reverse of the form to write down
possible comments or complaints. Try to be as accurate as possible in
writing the comments/complaints. This will allow maintenance
personnel to handle this adequately.
05-21-21 Flight Controls
Elevator/Aileron/Rudder/Flap
Check the elevator/aileron/rudder controls for smooth operation and
forces as expected. Do not apply full or abrupt control inputs at
speeds above VA (88 KIAS). While increasing speed do not allow the
speed to increase above VNE (126 KIAS), keep engine RPM within
limits. While decreasing speed do not stall the aircraft. Check controls
with all possible flap settings. DO NOT spin the aircraft! The
maximum speed with flaps intermediate and full flaps is 79 KIAS.
Longitudinal Trim
Operate the trim through the full range. It should be possible to trim
the aircraft in a speed range above 50 KIAS at Full throttle and flap up
as well as 65 KIAS at 3500 RPM and flap 30°. A larger trim range is
Chapter 05 Inspection and Maintenance
Issue: 04.APR 2016 Page 59
TOMARK, s.r.o.
Airplane Maintenance Manual
amongst other depending on the cg position. Check both full forward
and full aft trim. Stick forces change significant with trim setting. Fly
the trim test for nose up at low, for nose down at high speeds.
Lateral and Directional Trim
The aircraft should be adequately trimmed lateral and directional at a
cruise speed of 95 KIAS.
Flap Control
Check for proper functioning of the flap controls. This may be done
on the ground or in flight at an airspeed of less than VF (79 KIAS).
Select intermediate flap position then full flap position, verifying
visually that the flaps have deployed and retracted correctly.
05-21-22 Engine Controls
Throttle
Check the smooth operation of the throttle over its complete range
(check friction lock function). The engine should give a direct
response.
Engine Electric Control Switches
Check the operation of the engine key switch before takeoff according
to the AFM. Check operation of fuel pumps (mechanical from engine
and electric fuel pump) before takeoff according to the AFM.
05-21-23 Other Controls
Door Locks
Door locks are not tested in flight as such, however throughout the
engine RPM range the lock handles should be observed to ensure the
lock does not open due to vibrations.
Chapter 05 Inspection and Maintenance
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Airplane Maintenance Manual
Brake and Park Brake
Check the function of the brakes during taxi. Perform stops using the
brake to verify smooth and symmetric operation of the brakes. Set
the parking brake and perform a run up to verify that the parking
brake is operating correctly.
05-21-24 Flight Instruments
Magnetic Compass
Check presence, legibility and date of the compensation card. Check
the smooth functioning of the magnetic compass. A nervous or
otherwise unstable compass indicated a vibration or magnetic field
problem. One should be familiar with generic magnetic compass
turning errors in tuning or accelerating flight.
Airspeed/Altitude Indication
Check the logic and smooth functioning of the pitot/static related
indicators. While increasing speed do not allow the speed to increase
above VNE. While decreasing speed do not stall the aircraft. Indicated
situation should follow actual situation instantaneous. Lagging or
“sticking” indication is reason for complaint.
05-21-25 Avionics
COM
Check the correct functioning of the radio. Tune in to a frequency
given by ATC and check whether both receiving and transmitting
levels are acceptable.
XPDR
Check the functionality of the transponder. Ask a transponder code of
ATC and ask whether they receive the signal. They should check for
the primary and secondary signal including altitude. Try to send an
ident and ask ATC to reply via radio when they have received it.
Chapter 05 Inspection and Maintenance
Issue: 04.APR 2016 Page 61
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Airplane Maintenance Manual
05-21-26 System
General
Verify that the database is current. Verify that software settings are
applicable to the Viper SD-4 RTC and unchanged versus the
information contained in the flight manual.
Verify EMS page on RHS display is always on minimum 50% screen
layout.
Skyview Artificial Horizon
Check the logical functioning of the artificial horizon. It should be
possible to see the effects from both roll and pitch on the instrument
instantaneous and reflecting actual pitch and roll. The aircraft
indicator symbol should be adjustable both up and down.
Turn and Bank Indication
Check the logical functioning of the turn and bank indicator. It should
be possible to see the effects from both left and right bank on the
instrument. Furthermore check the functioning of the slip indicator.
Slipping the aircraft both to the left and to the right should result in a
logical indication. Check accuracy of the instrument by timing a full
360 turn.
GPS
Check the functionality of the GPS. See whether the reception of
satellite signals is sufficient. Furthermore check the navigation facility
by trying to navigate for a short period to an airfield or beacon in the
neighborhood which is available in the data base.
OAT Indicator
The OAT indicator shows the outside air temperature measured at the
interface between VST and HST. The temperature indication can be
correlated to the temperature ATC has available on the airfield at the
moment of take-off. The functionality can further be checked by the
fact that usually the temperature decreases with increasing altitude
(note that OAT values have a noticeable time delay – remain on level
Chapter 05 Inspection and Maintenance
Page 62 Issue: 04.APR 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
flight for several minutes). Be aware that in certain meteorological
conditions, the temperature will increase with increasing altitude
(inversion). If needed consult the meteo office for further information
on the day of the test. OAT indication should not change with any
change electric power or environment situation. Changed or erratic
OAT while transmitting on the Com radio indicates a degradation of
the sensor wire shielding.
Compass
Check agreement of SkyView compass display with magnetic compass
while executing turns.
Airspeed Indicator/Altimeter/Variometer
Check agreement of SkyView airspeed and altitude readings with
those of the analog instruments.
Accelerometer
Select the g-meter display and verify the indication to correlate with
bank angle in turning flight. There is no need to deliberately attempt
more than 2g (equivalent to coordinated turn with 60° bank and
constant speed).
Skyview Angle of Attack
Perform Skyview Angle of Attack calibration according the onscreen
instructions and Skyview Manual.
05-21-27 Engine Monitoring System (EMS)
EMS Check
Check functioning of EMS display. Prior to takeoff, follow startup and
run up procedure according to the AFM.
RPM Indication
Check the functioning of the rpm indication on the EMS display while
moving from low to high rpm and reverse.
Chapter 05 Inspection and Maintenance
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Airplane Maintenance Manual
Fuel Pressure Indication
Check the functioning of the fuel pressure indication on EMS display
by switching electric pump ON/OFF. Fuel pressure indication should
remain green in colour.
Oil Pressure and Temperature Indication
Check the functioning of the oil pressure and oil temperature
indication on the EMS display. Idle RPM will reduce the oil pressure
and increasing power settings will increase the pressure. Indication
should follow instantaneously.
Verify in stabilized full throttle climb flight at 65 KIAS that the
temperature remains within limits.
CHT Indication
Check the functioning of the CHT indication on the EMS display by
changing the throttle setting. In idle conditions the CHT of the various
cylinders will have a higher spread, in stabilized conditions above
4000RPM the difference between the two EGT signals should be no
more than 20 °C.
05-21-28 Other Instruments
Fuel Quantity Indicator
Check the functioning of the fuel quantity indicator by monitoring the
indication during the flight. During the flight the indication should
become less according the amount burned. The indication is only
accurate in horizontal flight; however the indication should be
independent of the airspeed. Changing indication with changing
speed gives reason to suspect a problem with the fuel ventilation and
should be investigated immediately.
Do not read the indicator in a turn, sideslip, steep climb or descent.
Volt/Amp Meter
Check the functioning of the volt/amp meter by switching MASTER
and INSTRUMENT on and electric consumers (lights) on prior to
engine start. The battery should be sufficient to maintain a Voltage
Chapter 05 Inspection and Maintenance
Page 64 Issue: 04.APR 2016
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Airplane Maintenance Manual
above 12V, the Ampere meter should show a discharge depending on
the amount of electric load. A regular twitch trigged by the ACL is
normal. The voltage should immediately increase to 13.6V when the
engine generator engages at engine speed above 2800 RPM, the
ammeter should immediately read a charging state.
05-21-30 Flight Handling Tests
These tests come closer to the boundaries of the flight envelope and
have to be tested with care. Gain sufficient altitude before starting
these tests. Do not execute these tests in inadequate weather
conditions. Do not omit this part of the maintenance check flight but
schedule an additional flight. The flight handling tests address four
items.
Normal Flight
In this item the pilot should comment on the normal flight handling.
He can base his judgement on the experience gained on the type in
previous flights. He should base his judgment on all items tested so
far in the maintenance check flight. He should address flight
handling, the possibility to trim the aircraft and the control authority.
High Speed
In this part of the test the pilot should fly speeds up to VNE. This
speed should be approached carefully with sufficient altitude left for
recovery since this speed will only be reached in a relatively steep
dive. Since there is a risk of over speeding the engine this has to be
flown at idle power setting. Check the rpm at VNE. This should not be
more than 5200 rpm. During the high speed flight, check for
excessive or unusual vibrations or buffeting. When unusual vibrations
are noticed, do not increase speed further. Gently pull out of the dive
and return to the airfield as soon as practical for inspection.
Stall
Approach the stall with a speed reduction of approximately 1knot/s.
Trim the aircraft at 65 KIAS before starting this maneuver. When the
airplane stalls, recover the aircraft in a normal way. This has to be
done in a configuration with the flaps up and the power set to idle.
Chapter 05 Inspection and Maintenance
Issue: 04.APR 2016 Page 65
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Inspection after Spin-Event
Check play in flap system (check in all flap positions and on both sides of
the aircraft).
No excessive play allowed (max. 3 mm movement of flap trailing edge).
○
Unmount LH and RH seat.
○
Inspect rivet connections of torsion tube close to RH and LH fuselage
sidewall (use mirror).
○
Retract and extend flaps and inspect for smooth operation / inspect rivet
connections during operation
○
Inspect rivet connection at center bellcrank attachment (electric flap drive)
○
Inform in TOMARK in case of finding and request instructions.
○
Otherwise re-mount the seat.
○
Document the (pilot-owner) inspection after spin-event in aircraft logbook.
○
Perform Aircraft Geometry Check according to Chapter 05-50-02
○
Issue: 11.AUG 2016
Airplane Maintenance Manual
The stall speed found in the tests should correlate to the stall speed
indicated in AFM.
05-50 Unscheduled Maintenance
In case of any event such as hard landing, structural overload, lighting
or propeller ground strike which warrants inspection or repair beyond
what is defined in this issue contact TOMARK.
05-50-01 Inspection after Spin-Event
The Viper SD-4 RTC is not approved for spinning. However if a spinevent has occurred the following inspection must be performed prior
to the next flight.
This inspection can be performed as a pilot-owner inspection (Refer
to COMMISSION REGULATION (EC) No 2042/2003, M.A.803 Pilotowner authorization).
Chapter 05 Inspection and Maintenance
Page 66 Issue: 04.APR 2016
TOMARK, s.r.o.
Aircraft Geometry Check Form
Measuring sections
Prescribed section
distance ± tolerance
Measured value
Symmetry of vertical and horizontal surfaces:
1. AL = distance between measuring points 6 – 3
1345 mm ± 3mm
2 .AR = distance between measuring points 6 – 3
1345 mm ± 3mm
3. BL = distance between measuring points 6 – 9
1900 mm ± 3mm
4. BR = distance between measuring points 6 – 9
1900 mm ± 3mm
5. CL = distance between measuring points 7 – 8
1337 mm ± 3mm
6. CR = distance between measuring points 7 – 8
1337 mm ± 3mm
7. DL = distance between measuring points 6 – 2
2467 mm ± 5mm
8. DR = distance between measuring points 6 – 2
2467 mm ± 5mm
Wing symmetry and twist:
9. EL = distance between measuring points 3 – 5
3553 mm ± 5mm
10. ER = distance between measuring points 3 – 5
3553 mm ± 5mm
11. FL = distance between measuring points 3 – 4
3855 mm ± 5mm
12. FR = distance between measuring points 3 – 4
3855 mm ± 5mm
13. GL = distance between measuring points 4 – 2
3049 mm ± 5mm
14. GR = distance between measuring points 4 – 2
3049 mm ± 5mm
15. HL = distance between measuring points 5 – 1
3188 mm ± 5mm
16. HR = distance between measuring points 5 – 1
3188 mm ± 5mm
Issue: 11.AUG 2016
Airplane Maintenance Manual
05-50-02 Aircraft Geometry Check
Perform the Aircraft Geometry Check after major events such as hard
landings, spinning etc. but also after dismounting of the surfaces.
▶ Measure the distances as outlined in
Figure 4 Measuring Points Identification
Figure 3 Measuring Sections
and enter values into the form
below.
▶ Contact TOMARK if any measured value exceeds tolerances.
Measuring sections and points on the right aircraft side are
symmetrically to the left side. Sections on the right side are marked
“AR” thru “HR”.
and
Issue: 04.APR 2016 Page 67
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Issue: 11.AUG 2016
Airplane Maintenance Manual
Figure 3 Measuring Sections
Chapter 05 Inspection and Maintenance
Page 68 Issue: 04.APR 2016
TOMARK, s.r.o.
Issue: 11.AUG 2016
Airplane Maintenance Manual
Figure 4 Measuring Points Identification
Issue: 04.APR 2016 Page 69
Chapter 05 Inspection and Maintenance
TOMARK, s.r.o.
Airplane Maintenance Manual
06 Dimensions and Areas
06-00 General
06-00-01 Coordinate System
The level attitude is defined by the horizontal orientation of the
canopy frame.
06-10 Main Data
06-10-01 External Dimensions
Length: 6.400 m
Height: 2.200 m
Wing span: 8.340 m
06-10-02 Wing
Area: 10.450 m2
Wing chord 1.290 m
Aspect ratio: 6.6
Wing profile: NACA 4415
Wing platform: rectangular
Incidence angle: 3
Dihedral: 3
Sweep angle: 0
Wing twist: 0
06-10-03 Aileron
Area: (each) 0.260 m2
Span: (each) 0.960 m
Chord: 0.270 m
Chapter 06 Dimensions and Areas
Page 70 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
06-10-04 Aileron Trim Tab
Span 301 mm
Chord 65 mm
06-10-05 Flap
Type: slot
Area: (each) 0.560 m2
Span: (each) 2.197 m
Depth: 0.255 m
06-10-06 Horizontal Tail
Area: 2.220 m2
Span: 2.800 m
Chord: 0.785 m
Platform: rectangular
Profile: NACA 0010
Incidence angle: -1.5°
Dihedral: 0
Leading edge sweep angle: 0
Twist: 0
06-10-07 Elevator
Area: 0.750 m2
Span: 2.600 m
Chord: 0.320 m
06-10-08 Elevator Trim Tab
Span 928 mm
Chord 86 mm
06-10-09 Vertical Tail
Area: 1.178 m²
Height: 1.300 m
Chapter 06 Dimensions and Areas
Issue: 11.AUG 2016 Page 71
TOMARK, s.r.o.
Airplane Maintenance Manual
Root Chord: 1.122 m
Tip Chord: 0.587 m
Platform: trapeze
Profile NACA 0010
06-10-10 Rudder
Area: 0.560 m²
Leading edge sweep angle: 35
Trailing edge sweep angle: 11
06-10-11 Fuel System
Fuel tank capacity: 2 x 50 litres
06-10-12 Landing Gear
Track width: 2.190 m
Wheel base: 1.270 m
Main wheels: 4.00 – 6 (Kašpar K-226A-000 6’’)
Nose wheel: 4.00 – 6 (Kašpar K-116A-000 6’’)
06-10-13 Propeller
Number of blades: 3
Diameter: 1.650 m
Chapter 06 Dimensions and Areas
Page 72 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
07 Lifting and Shoring
Generally one wheel is lifted from ground as shown in the following.
If applicable (e.g. for placing the aircraft on scales) lift one wheel after
another.
07-00-01 Lifting a Main Wheel
▶ Generally work with to persons lifting a wing.
▶ Apply parking brake.
NOTICE Damage to the wing surface possible.
▶ Do not push on unsupported surface areas.
▶ Always place hands next to the wing main spar and the ribs.
▶ Lift the main wheel by pushing up the applicable wing side by hand in
areas as shown in the following figure:
▶ If applicable place the wheel on a scale or jack aircraft side as per
Chapter
Issue: 11.AUG 2016 Page 73
07-10-01 Jacking the Aircraft Side
.
Chapter 07 Lifting and Shoring
TOMARK, s.r.o.
Airplane Maintenance Manual
07-00-02 Lifting the Nose Wheel
▶ Apply parking brake.
NOTICE Damage to the horizontal stabilizer surface possible.
▶ Do not push on unsupported surface areas.
▶ Always place hands next to the horizontal stabilizer main spar and the
ribs.
▶ Lower the aircraft tail as far as necessary by pushing down the
horizontal stabilizer by hand in areas as marked:
▶ Place the nose wheel on scale or jack aircraft front as per Chapter
10-02 Jacking the Aircraft Front
Chapter 07 Lifting and Shoring
Page 74 Issue: 11.AUG 2016
.
07-
TOMARK, s.r.o.
Airplane Maintenance Manual
07-10 Jacking
07-10-01 Jacking the Aircraft Side
▶ Ensure parking brake is applied.
▶ Lift applicable wheel.
▶ Place a cushioned jack in the marked area (1) under the fuselage as
shown in the following figure (opposite side symmetrically).
Chapter 07 Lifting and Shoring
Issue: 11.AUG 2016 Page 75
TOMARK, s.r.o.
Airplane Maintenance Manual
07-10-02 Jacking the Aircraft Front
▶ Ensure parking brake is applied.
▶ Lift the nose wheel.
▶ Place a cushioned jack in the marked area (1) under the fuselage as
shown in the following figure.
Chapter 07 Lifting and Shoring
Page 76 Issue: 11.AUG 2016
TOMARK, s.r.o.
Mark
Definition
0
reference plane, identical with the plane of the airplane’s
wing’s leading edge in the horizontal attitude of the
airplane.
mR
weight on the right wheel of the main landing gear
mL
weight on the left wheel of the main landing gear
mF
weight on the wheel of the front landing gear
mT
total weight of the airplane, equal to mR + mL + mF
xT
distance of the CG from the leading edge
T
centre of gravity
LF
distance of the front landing gear wheel axis from the
wing’s leading edge
LM
distance of the main landing gear wheel axis from the
wing’s leading edge
L
landing gear base
MAC
mean aerodynamic chord (1,29 m)
Airplane Maintenance Manual
08 Leveling & Weighing
08-10 Weighing and Balancing
Definitions and Markings
xT = ((mR + mL) · LM – LF · mF)/m
Issue: 11.AUG 2016 Page 77
T
Chapter08 Leveling & Weighing
TOMARK, s.r.o.
MAC
1.29 m
Design limit of operational CG range
24 - 32% MAC
Airplane Maintenance Manual
The position of the centre of gravity expressed in % of the mean
aerodynamic chord bMAC is then calculated on the basis of the
formula:
Calculation Formulae
The procedure below is aimed to calculate the position of the max
fwd and max rear CG for this individual airplane. Once it is verified
that they fall between the design limits CG range of table below, then
this means that the CG will always be between the design CG limit
during any phase of the flight. It is nevertheless responsibility of the
pilot to make sure that the MTOM is not exceeded (See section 2). In
case a modification is performed on the airplane the procedure
should be repeated and the values recorded.
xT [% MAC] = xT / MAC · 100 %
For the calculation of the CG position it is necessary to know the
length of the mean aerodynamic chord (MAC). The calculated CG
position must be within the range specified by the manufacturer.
Weighing Procedure
When establishing the CG position and the subsequent calculation of
the CG position as % MAC proceed as follows:
NOTE Weigh the aircraft only on even floor and in closed shops (wind
protected). Use identical scales.
▶ Put the airplane on three scales as per Chapter
▶ Level the aircraft as per Chapter
Weighing of the airplane for the establishment of the allowed frontmost CG position:
08-20Leveling
07 Lifting and Shoring
.
.
▶ Completely fill fuel tanks.
▶ Ensure aircraft’s luggage compartment is empty.
▶ Occupy the pilot’s seat with the minimum allowed weight (55 kg).
▶ Read the weight readings of the scales under the wheels of the main
landing gear (mR and mL respectively).
▶ Read the weight reading of the scale under the wheel of the front
landing gear.
Chapter 08 Leveling & Weighing
Page 78 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
You will get the total weight of the airplane as the sum of mR+mL+mF.
▶ Calculate the distance of the CG from the wing’s leading edge by
using the formula:
xT = ((mR + mL) · LM – LF · mF)/mT.
▶ Calculate the front-most position as % MAC by using the formula:
xT [% MAC] = xT / MAC · 100 %.
Weighing of the airplane for the establishment of the rear-most CG
position as % MAC:
▶ Put 2 × 7,5 kg weights into the luggage compartments
▶ Fill the tanks with the minimum allowed take off fuel quantity (for a
30-minute flight).
▶ Load both seats with the maximum allowed crew weight that will
cause the airplane to reach its MTOM of 600 kg).
The weighting procedure is the same as in the case of establishing of
the front-most CG position.
The calculation procedure is the same as in front-most CG position
with correction on the maximum permissible weight of 15 kg of
luggage. The correction value of momentum on the maximum
permissible weight of luggage in the luggage compartment is 21 kg.
▶ Complete the following weighing record.
Chapter08 Leveling & Weighing
Issue: 11.AUG 2016 Page 79
TOMARK, s.r.o.
Signature
Note
CG positions
Empty Weight
Date
Airplane Maintenance Manual
Weighing Record
Chapter 08 Leveling & Weighing
Page 80 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
08-20 Leveling
The reference line for longitudinal leveling is the straight part of the
canopy frame.
The identical distances of wing tips to an even floor are the reference
for lateral leveling.
▶ Place aircraft on an even floor.
▶ Measure distances of wing tips to an even floor.
▶ Align a spirit level towards the straight part of the canopy frame.
▶ Place suitable wooden strips under the respective tires.
Chapter08 Leveling & Weighing
Issue: 11.AUG 2016 Page 81
TOMARK, s.r.o.
Airplane Maintenance Manual
12 Servicing
12-10 Replenishing
12-10-01 Refueling/Defueling
DANGER Risk of explosion.
▶ Never refuel or defuel the aircraft with engine running.
▶ Always ensure that the aircraft is grounded before refueling or
defueling.
▶ Ensure that no one is smoking within 100 feet of the aircraft.
▶ Ensure that all aircraft electrical systems are deenergized while
refueling or defueling.
▶ Ensure that no aircraft radar or powerful transmitters are operating
within 100 feet of the aircraft during refuelling or defueling.
▶ Do not fill individual tanks more than 90% of their maximum volume
at outside temperature exceeding 25 °C in order to avoid excessive
spillage due to thermal expansion.
▶ If fuel is spilled, ensure that the area of spillage is thoroughly flushed
with water and that all residual fuel and vapour have dissipated or
neutralized prior to starting the aircraft engine.
▶ Refuel the aircraft by pumping or pouring fuel into the wing tanks
through their filler caps.
▶ Using appropriate containers, defuel the aircraft by opening both
wing tank drain valves and the gascolator drain valve.
12-10-02 Oil Change
Follow the procedures as presented in chapter
ROTAX Maintenance Manual (Line)
Publications
Due to the position of the gascolator it might be difficult to drain the
oil tank by removing the oil drain screw. For that reason it is advisable
to remove the oil tank from aircraft for draining. Refer to the removal
procedure as outlined in Chapter
Chapter 12 Servicing
Page 82 Issue: 11.AUG 2016
) observing the following:
(refer to Chapter
79-10-01 Oil Tank
12-20-00 of the
01-30 Related
.
TOMARK, s.r.o.
Airplane Maintenance Manual
12-10-03 Coolant Replacement
Follow the procedures as presented in chapter
ROTAX Maintenance Manual (Line)
Publications
Coolant: SHERON Antifreeze Ultra G12++ or equivalent.
The lowest point of the Viper SD-4 RTC cooling system is the RH
fitting of the water cooler. If the cooling system shall be drained
completely carry out the following steps:
CAUTION Burns possible due to hot coolant.
▶ Allow coolant to cool down before working on the cooling system.
▶ Place a suitable container under the water cooler.
▶ Disconnect the hose connected to the RH fitting and drain coolant.
▶ Reinstall the hose.
The overflow bottle has to be drained and refilled separately:
CAUTION Burns possible due to hot coolant.
) observing the following:
12-20-00 of the
(refer to Chapter
01-30 Related
▶ Allow coolant to cool down before working on the overflow bottle.
▶ Place a suitable container under the overflow bottle.
▶ Drain overflow bottle by disconnecting the coolant hose.
▶ Connect the coolant hose.
▶ Refill coolant.
12-10-04 Brake Fluid Bleeding
WARNING Brake fluid is toxic and can cause disease!
▶ Do not allow brake fluid to come in contact with your skin.
▶ In case of accidental contact flush with water immediately.
NOTICE Brake fluid can damage paint or other material.
▶ Cover the affected areas with appropriate clothes or suitable
containers.
▶ Clean up immediately spilt brake fluid.
Carry out the following procedure generally with two persons. One
(upper) person sitting in the cockpit, one (lower) person next to the
main wheel.
Chapter12 Servicing
Issue: 11.AUG 2016 Page 83
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Airplane Maintenance Manual
▶ Start with one wheel.
▶ Remove wheel fairing as per Chapter
▶ Remove brake cylinder without disconnecting the brake line as per
Chapter
▶ Ensure brake cylinder handle is completely released.
▶ Place a suitable container under the brake.
▶ Disconnect brake hose from brake.
▶ Open the brake cylinder outflow valve and allow brake fluid to spill
into the container.
▶ Close brake cylinder outflow valve.
▶ Repeat this procedure for the other side as applicable.
12-10-05 Brake Fluid Replenishing
32-40-03 Brake Cylinder
32-40-01 Main Wheel Fairing
.
.
WARNING Brake fluid is toxic and can cause disease!
▶ Do not allow brake fluid to come in contact with your skin.
▶ In case of accidental contact flush with water immediately.
NOTICE Brake fluid can damage paint or other material.
▶ Cover the affected areas with appropriate clothes or suitable
containers.
▶ Clean up immediately spilt brake fluid.
Brake fluid: DOT3 HD 230 Liquid,
Standards: ISO 4925 DOT3 SAEJ 1703F, FM VSS 116
Carry out the following procedure generally with two persons. One
(upper) person sitting in the cockpit, one (lower) person next to the
main wheel.
▶ Start with one wheel.
▶ Remove wheel fairing as per Chapter
▶ Remove brake cylinder without disconnecting the brake line as per
Chapter
▶ Ensure brake cylinder handle is completely released.
▶ Ensure the brake cylinder outflow valve is the highest point of the
brake cylinder during the complete procedure.
▶ Install a clear hose of about 60 cm length to the brake cylinder
outflow valve and secure with a wire.
32-40-03 Brake Cylinder
32-40-01 Main Wheel Fairing
.
.
Chapter 12 Servicing
Page 84 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
▶ Put the free end of the clear hose in a suitable container which can be
placed on the cockpit floor.
▶ Install a clear hose to the brake valve and secure with a wire.
NOTE To prevent air bubbles in the brake system keep it always slightly
under pressure. For that reason, the brake cylinder outflow valve shall
not be opened before the lower person has opened the brake valve
and has begun to press hydraulic fluid into the system.
▶ Open the valves in the correct sequence (brake valve first) using a
wrench and replenish brake fluid by pressing it from the bottom
(wheel) to the top (brake cylinder).
▶ Watch the brake fluid spilling into the container.
▶ If brake fluid is clear and free from air bubbles, close the valves in the
correct sequence (brake cylinder valve first).
▶ Repeat this procedure for the other wheel.
▶ Lock brake lever in first position and thus keep brake system under
pressure for about one hour.
▶ Check tightness of the brake system. Seal system where necessary.
▶ Remove clear hoses from the valves.
▶ Adjust brake linings as per Chapter
▶ Reinstall brake cylinder as per Chapter
▶ Reinstall wheel fairings as per Chapter
32-40-05 Brake Linings
.
32-40-03 Brake Cylinder
32-40-01Main Wheel Fairing
.
.
Chapter12 Servicing
Issue: 11.AUG 2016 Page 85
TOMARK, s.r.o.
Airplane Maintenance Manual
20 Standard Practices-Airframe
20-10-01 Bolts
For torque of bolts refer to the TOMARK regulation “Bolted joints of
Viper SD-4 RTC” (Can be downloaded from TOMARK website
www.vipersd4.com).
Mark the position of all bolted joints with red sealing varnish after
locking.
20-10-02 Rivets
General
Riveted parts are used in design of Viper SD-4 RTC airplane for whole
fuselage, wings, flaps, ailerons and tail unit. In the following table
there is a survey of rivets that are used on Viper SD-4 RTC airplane
structure.
Chapter 20 Standard Practices-Airframe
Page 86 Issue: 11.AUG 2016
Type of rivets
Designation
Use
POP UP RIVET
EN 14588 series 1031 - 3,2x4,0
Fuselage, wing,
stabilizer,
elevator, rudder,
flaps, ailerons
POP UP RIVET
EN 14588 series 1051 - 3,0x8,0
POP UP RIVET
EN 14588 series 1051 - 4,0x13,0
POP UP RIVET
EN 14588 series 1051 - 4,0x16.0
POP UP RIVET
EN 14588 series 1051 - 4,0x20,0
POP UP RIVET
AVEX series 1002 - 3,2x8,0
POP UP RIVET
AVEX series 1002 - 4,0x10,0
POP UP RIVET
AVEX series 1004 - 3,2x8,0
POP UP RIVET
AVEX series 1004 - 3,2x12,2
POP UP RIVET
AVEX series 1604 - 4,0x11,2
POP UP RIVET
AVEX series 1661 - 3,2x9,5
POP UP RIVET
AVEX series 1691 - 3,2x6,0
POP UP RIVET
AVEX series 1691 - 3,2x7,9
POP UP RIVET
AVEX series 1691 - 3,2x11,2
POP UP RIVET
AVEX series 1691 - 3,2x12,0
POP UP RIVET
AVEX series 1691 - 3,2x14,0
POP UP RIVET
AVEX series 1691 - 4,0x8,0
POP UP RIVET
AVEX series 1691 - 4,0x 9,5
POP UP RIVET
AVEX series 1691 - 4,0x12,0
POP UP RIVET
AVEX series 1691 - 4,0x12,7
POP UP RIVET
AVEX series 1691 - 4,0x14,0
POP UP RIVET
AVEX series 1691 - 4,0x16,7
POP UP RIVET
AVEX series 1691 - 4,0x18,0
POP UP RIVET
SR series 1201 - 3,2x6,5
POP UP RIVET
SR series 1201 - 3,2x8,0
POP UP RIVET
AVINOX II series BE61 - 3,2x9,2
POP UP RIVET
AVINOX II series BE61 - 3,2x11,5
POP UP RIVET
AVINOX II series BE61 - 4,0x7,5
POP UP RIVET
AVINOX II series BE61 - 4,0x9,5
POP UP RIVET
AVINOX II series BE61 - 4,0x12,5
POP UP RIVET
HEMLOK series 2221 - 6,5x14,3
SOLID RIVET
DIN 661 - 4x20
SOLID RIVET
DIN 661 - 4x24
SOLID RIVET
Nit AN470AD5-14
TOMARK, s.r.o.
Airplane Maintenance Manual
Issue: Issue: 11.AUG 2016 Page 87
Table 1 Survey of rivets used in airplane structure
In case that different replacement rivets are used than shown in the
Table 1 Survey of rivets used in airplane structure then rivet
dimensions must be identical with originally used rivets and material
of rivets must fulfil the same material characteristics.
Chapter20 Standard Practices-Airframe
TOMARK, s.r.o.
Airplane Maintenance Manual
Removal
NOTE Observe the following when removing rivets:
▶ Use a drill bit by 0.6 mm (0.025 in) diameter smaller than the rivet
shank and rill up to the depth of 2/3 of the total depth riveted parts.
▶ Remove the drilled heads with a sharp cuter.
▶ Drive out the shank with the soft material mandrel diameter by 0.1
mm (0.004 in) smaller than rivet shank diameter.
▶ The rivets, which cannot be driven out should be drilled out full
depth.
▶ When removing rivets, be careful that chips and rivets do not fall
down to areas were sensitive mechanisms are located, e.g. guides,
control bearings etc.
▶ Remove rivets from the side of the rivet, which is more accessible.
▶ Drill out the rivet head and drive out the shank.
Riveting Procedure
NOTE Observe the following when riveting:
▶ When drilling, fix by clamps or clecos mutual position of assembled
parts.
▶ Holes of higher diameters pre-drill with a drill bit of smaller diameter
and then re-drill them to the final size.
▶ Fit the parts being connected and drill them together. Hole diameter
must be by 0.1 mm (0.004 in) bigger than rivet shank diameter.
▶ Disassemble the parts and deburr the holes.
NOTE Observe the following for sunken rivets:
▶ Perform conical countersinking of the rivet head by 5° smaller apex
angle (e.g. the head with angle of 100° will have countersinking of
95°±1°).
After countersinking, the cylindrical part of hole with min. length of
0.3 mm (0.012 in) must remain in material.
▶ Countersinking must be performed in such a way that the rivets head
overruns the area before riveting max. by 0.2 mm (0.008 in), the rivet
head must not be under the surface level (sunk).
▶ Before applying the bonding sealant (applies to fuel tank only)
carefully clean the connected parts of impurities and degrease contact
surfaces by appropriate agent, e.g. industrial spirit.
Chapter 20 Standard Practices-Airframe
Page 88 Issue: 11.AUG 2016
TOMARK, s.r.o.
System
Line type
Connection type
Fuel (firewall forward)
Hose
Hose clamps
Fire sleeves
Fire protection tape
Fuel (aft of firewall)
Tube (aluminium)
Fittings
Oil
Hoses
Hose clamps
(Rotax or worm drive)
Fire sleeves
Fire protection tape
Airplane Maintenance Manual
NOTE For cleaning and degreasing:
▶ Use a clean paper towel or cloth. After wiping, the towel or cloth must
not show any contamination.
▶ For perfect degreasing the whole surface, clean always smaller part of
surface, after its perfect cleaning continue on.
▶ Cleaning liquid always apply on the cloth only and wipe it off from the
surface before its evaporating.
NOTE The surfaces that are to be connected must be dry.
▶ Clean before application of bonding sealant.
▶ Apply bonding sealant on one of the surfaces (applies to fuel tank
only), which should be sealed together.
▶ Apply the adhesive directly from the packing by means of the
extrusion gun, plastic spatula or paintbrush in such a way that the
layer of sealant is equally thick and integral, without bubbles or
uncovered areas. The optimum thickness of the applied coat is 0.25
mm (0.01 in).
▶ After applying bonding sealant connect both parts together, fix them
by clecos and rivet them.
NOTE After proper riveting the continual bur of adhesive is created on the
edge of connected surfaces. If this bur is big, it is possible to wipe it
off with the plastic spatula and finally with cloth dipped in degreasing
agent.
20-10-03 Hoses and Tubes
The hoses and tubes used on the Viper SD-4 RTC are connected in
different ways as presented in the following table:
Issue: Issue: 11.AUG 2016 Page 89
Chapter20 Standard Practices-Airframe
TOMARK, s.r.o.
Air
Hose
Hose clamps
Brake
Hose
Fitting, joint with
incise ring and
interposition hose
(Kašpar)
Airplane Maintenance Manual
20-10-04 Bowden Cables
Removal
▶ Note position of cable tie.
▶ Remove cable tie.
▶ Disconnect Bowden cable from actuator arm.
▶ Remove firewall seal from firewall penetration.
▶ Unscrew firewall penetration plastic grommet.
▶ Loosen the counternut of control knob.
▶ Pull out the Bowden cable.
Installation
▶ Install in reverse sequence of removal.
▶ Seal firewall penetration with PR 812 sealant.
▶ Check correct travel. Adjust travel if necessary.
Chapter 20 Standard Practices-Airframe
Page 90 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
21 Air Conditioning
21-20 Distribution
The ventilation of the cockpit of Viper SD-4 RTC is designed as a ram
pressure one, with the possibility to control the airflow.
The air entering through the cockpit air inlets (1) is directed by plastic
tubes to the air vents (2) above of the instrument panel and to two air
nozzles (3) located on left and right instrument panels. The air
nozzles are controllable with ability to be closed by rotary motion.
Canopy glass ventilation is supplied by two canopy air inlets (4). The
airflow is led to the air vents located on the front part of the cabin
frame and is adjustable by valves (5) located at the sides of canopy
frame.
The canopy is equipped with ventilation windows (6) on the sides.
Figure 5 Ventilation scheme diagram
Chapter 21 Air Conditioning
Issue: 11.AUG 2016 Page 91
TOMARK, s.r.o.
Item
Description
1
Cockpit air inlets
2
Air vents
3
Air nozzles located inside on left and right instrument panels
4
Control valves
5
Canopy air inlets
6
Ventilation windows
Airplane Maintenance Manual
21-40 Heating
The heating system consist of
a heat exchanger
a control valve
two selector boxes
rubber hoses
two Bowden cables
two control knobs.
Fresh air is taken from the inlet located on the bottom of the lower
engine cowling. Through rubber hoses (3) the air is routed to the heat
exchanger (5) at the exhaust muffler (4) and further to the selector
boxes (2).
The control valve is actuated via Bowden cable by the CABIN HEAT
control knob located on the right side of the instrument panel.
From the control valve air is ducted to the distribution box (6), where
the air flow is divided. Then further routed through rubber hoses (3)
to the flanges (2) on the left and right side of the firewall (1) and then
into the cabin.
Chapter 21 Air Conditioning
Page 92 Issue: 11.AUG 2016
TOMARK, s.r.o.
Item
Description
1
Firewall
2
Selector box
3
Rubber hoses
4
Exhaust muffler
5
Heat exchanger
Airplane Maintenance Manual
Figure 6 Heating System
Issue: 11.AUG 2016 Page 93
Chapter 21 Air Conditioning
TOMARK, s.r.o.
Airplane Maintenance Manual
24 Electrical Power
24-00 General
The electrical system is a 12V DC system.
The system consists of
AC generator with rectifier
Battery
Fuses
Circuit breakers
Switches
Indication lights
For wiring overview and partial diagrams refer to Chapter
and also Chapter
00-10 List of Figures
24-30 DC Generation
24-30-10 Generator
The electrical system is supplied by an in-built AC generator with a
rectifier (12 V/22 A DC). This generator is part of the engine
installation (refer to Rotax documentation).
24-30-20 Battery
The battery (VARTA 519901017) is an auxiliary source of electric
energy, located in the engine compartment on the left lower side of
the firewall. It is accessible after the removal of the upper engine
cowling.
91 Charts
.
The cockpit is equipped with an on-board 12V electric socket, located
on the right instrument panel. The socket can be used for charging of
the aircraft battery.
Chapter 24 Electrical Power
Page 94 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
24-30-30 Signaling
A regulator/generator failure is signalled by a red warning light on the
left hand side instrument panel.
24-60 Distribution
24-60-10 Electric Current Protection
The electric system consists of electric circuits protected by circuitbreakers and the main 125 A melting fuse.
Chapter 24 Electrical Power
Issue: 11.AUG 2016 Page 95
TOMARK, s.r.o.
Airplane Maintenance Manual
25 Equipment and Furnishings
25-10 Flight Compartment
25-10-01 Seats
The seats are of one piece and attached to fuselage structure by for
Allen screws each. The seat-contact surface is attached to the seat by
means of hook-and-loop fasteners).
Removal
▶ Remove the seat-contact surface (hook-and-loop fastener).
▶ Remove the seats (4 Allen screws each).
Installation
▶ Install in reverse sequence of removal.
25-10-02 Seat Belts
Viper SD-4 RTC provides a SCHROTH, 4-03-D802xx Type, 3-point
static harness restraint system.
The strap ends of the seat belts are attached to riveted brackets on
the main fuselage spar.
The strap ends of the shoulder harnesses are attached to riveted
brackets on the upper aft fuselage structure.
25-10-03 Paneling
The paneling inside the cockpit where not glued is generally attached
to the fuselage by means of hook-and-loop fasteners.
Chapter 25 Equipment and Furnishings
Page 96 Issue: 11.AUG 2016
TOMARK, s.r.o.
Airplane Maintenance Manual
25-50 Baggage Compartment
Baggage area is located in the cockpit right behind the pilot seats.
Area for baggage is divided into two storage parts and is integrated
into the fuselage. Both parts are covered by manually operated open/close roller hard plastic blinds guided in rails over the full
length.
Chapter 25 Equipment and Furnishings
Issue: 11.AUG 2016 Page 97
TOMARK, s.r.o.
Aileron deflection angle
up +27° ± 1°
down -16° ± 1°
Elevator deflection angle
up +25° ± 1°
down -20° ± 1°
Flap deflection angle
0° ± 2°
15° ± 2°
30° ± 2°
[40°1 ± 2°]
Rudder deflection angle
left +30° ± 1°
right -30° ± 1°
Elevator’s trim tab
deflection angle
up +21° ± 2°
down -33° ± 2°
Aileron´s trim tab
deflection angle
up +28° ± 2°
down -28° ± 2°
1
Airplane Maintenance Manual
27 Flight Controls
The airplane is equipped with a complete dual control system for
elevator, aileron and rudder. Standard control elements - control stick
and rudder pedals - are used for aerodynamic control.
The control sticks control the ailerons and the elevator. The foot
control pedals control the rudder and the front landing gear wheel.
The wing flaps are actuated electrically by a lever-type controller.
Control Surface Deflections
Table 2 Control surface deflections
Chapter 27 Flight Controls
Page 98 Issue: 11.AUG 2016
Not used for normal operation
TOMARK, s.r.o.
Item
Description
Item
Description
1
Rudder
4
Ailerons
2
Elevator
5
Control sticks
3
Flaps
6
Pedals
Airplane Maintenance Manual
Figure 7 Control system
Chapter 27 Flight Controls
Issue: 11.AUG 2016 Page 99
TOMARK, s.r.o.
Airplane Maintenance Manual
27-00-01 Control Stick
Removal/Installation
▶ Remove seat as per Chapter
▶ Note position of electrical wiring cable ties.
▶ Cut cable ties of electrical wiring.
▶ Disconnect electrical wiring.
▶ Loosen clamp (1 bolt).
▶ Remove control stick (1 bolt).
▶ Install in reverse sequence of removal.
27-00-02 Control Rod
The control rods used in the Viper SD-4 RTC control system are
equipped with two kinds of rod ends:
fork end
ball bearing rod end.
The control rod attachment to the respective control levers and
control surfaces is done generally with a typical castle nut bolt
connection.
25-10-01 Seats
.
Removal
▶ Remove bonding lead (if present) from rod end (1 Allen screw with
locking washer).
▶ Note position of bolt side and washer.
▶ Disconnect rod end (1 bolt with castle nut and washer).
Installation
▶ Install in reverse sequence of removal.
27-00-03 Bell Crank
Bell cranks are used to transfer control inputs to the control rods.
Chapter 27 Flight Controls
Page 100 Issue: 11.AUG 2016
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