iKarus C42 Series Maintenance Manual
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iKarus C42 Series Maintenance Manual

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Maintenance Manual
IKARUS C42 Series
C42E
COMCO IKARUS GmbH
Am Flugplatz 11
D-88367 Hohentengen
Germany
Telephone +49 (0) 7572 – 60080
COMCO IKARUS
Put the fun back into flying
C42 / C42B / C42C
C42 UK / C42B UK /
(C42B LSA) /
Issue VII Revision No.: 1
from 18.February 2014

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Summary of Contents for iKarus C42 Series

  • Page 1 COMCO IKARUS Put the fun back into flying Maintenance Manual IKARUS C42 Series C42 / C42B / C42C C42E C42 UK / C42B UK / (C42B LSA) / Issue VII Revision No.: 1 from 18.February 2014 COMCO IKARUS GmbH Am Flugplatz 11...
  • Page 2 COMCO IKARUS cannot accept liability for the topicality, correctness, completeness or quality of the information given in the maintenance manual. Any liability claims against COMCO IKARUS which relate to material or non- material damage and which may be caused by the usage or non-usage of...
  • Page 3 They do, however, depict parts with the same or similar function. The information and descriptions of components and systems given in this manual are correct at the time of publishing. COMCO IKARUS follows a policy of constant improvement. However, there is no policy of mandatory retro-fitting for earlier products.
  • Page 4 COMCO IKARUS Maintenance Manual C42 Series Log of revisions No. Change Page Issue Date Signature Brake 21 - 22 Issue II Dec. 2010 A.Kurz Picture 46 u. 56 Issue II Dec. 2010 A.Kurz Appendix 6: 6.2.3 Brake fluids Issue II Jan.

  • Page 5: Table Of Contents

    COMCO IKARUS Maintenance Manual C42 Series Table of Contents Introduction ....................5 Overview on maintenance ..................5 Carrying out maintenance work ................6 Technical description ................7 Equipment List ......................11 2.1.1 Optional Items ........................12 2.1.2 Installation manual for Optional Items ................13 2.1.2.1...
  • Page 6 COMCO IKARUS Maintenance Manual C42 Series Cockpit and instruments ..................46 Movable connections, particularly in the flight controls ........46 Servicing the C42 ..................48 General maintenance information ...............48 4.1.1 Safety elements ....................... 48 4.1.2 Screw connections ......................48 4.1.3 Welded joints ........................50 4.1.4...
  • Page 7 COMCO IKARUS Maintenance Manual C42 Series Repairing the glass-fibre / carbon-fibre skins ............92 Electrical repairs ....................93 Ikarus Flight Centres ....................93 Appendix ....................94 Operating fluids ....................94 6.1.1 Engine oil ......................... 94 6.1.2 Coolant ..........................94 6.1.3 Brake fluid ........................94 Settings .........................94...
  • Page 8 Maintenance Manual C42 Series Foreword It is with much pleasure that we welcome you into the group of IKARUS C42 owners. The C42 is a solid micro-light aircraft which has proven itself in daily use. It is the result of many years of development and contains the experience gained in the production of more than 3000 micro-light aircraft.

  • Page 9: Introduction

    COMCO IKARUS Maintenance Manual C42 Series 1 Introduction 1.1 Overview on maintenance The operational safety of an aircraft depends not only on its design parameters and operating conditions but also on proper care and maintenance. Maintenance includes all inspections, servicing and repairs and must be carried out at regular intervals.

  • Page 10: Carrying Out Maintenance Work

    Maintenance work must always be carried out by a properly qualified person. COMCO IKARUS has an extensive sales and maintenance network. We recommend that you commission an IFC (Ikarus Flight Centre) or an ISC (Ikarus Service Centre) close to you with the maintenance of your aircraft.

  • Page 11: Technical Description

    COMCO IKARUS Maintenance Manual C42 Series 2 Technical description The IKARUS C42 Series and the IKARUS C52 are single-engine, two-seater, high- wing micro-light aircrafts. They are not designed for aerobatics. The aircrafts have a 3-axis control system and high-lift wing flaps. They have a tricycle landing gear with a steerable nose wheel. The wings are easy to rig and de-rig.
  • Page 12 COMCO IKARUS Maintenance Manual C42 Series Figure 3: Ikarus C42C MaintenanceManual C42- Revison No.:1 8 from 107 Series_Issue_VII_18.02.2014.doc...
  • Page 13 COMCO IKARUS Maintenance Manual C42 Series Figure 4: Three-view Ikarus C42 / C42 UK Figure 5: Three-view C42B / C42 B UK/ C42E MaintenanceManual C42- Revison No.:1 9 from 107 Series_Issue_VII_18.02.2014.doc...
  • Page 14 COMCO IKARUS Maintenance Manual C42 Series Figure 6: Three-view C42C MaintenanceManual C42- Revison No.:1 10 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 15: Equipment List

    COMCO IKARUS Maintenance Manual C42 Series 2.1 Equipment List This equipment list gives an approximate description of the C42 aircraft. Design: Landing gear, fuselage, wings, struts and empennage are of certified, high-strength aluminium tubing. Fittings and screws are of stainless steel or of high-strength standard elements.

  • Page 16: Optional Items

    COMCO IKARUS Maintenance Manual C42 Series 2.1.1 Optional Items Refer to POH for types cleared for use Propellors Carbon Fibre Shells (saves 4kg) Airframe Wingtips Lightweight Version (White only) Wingtips Coloured (Red or Blue) VLA only Scratch Resistant Front Window...

  • Page 17: Installation Manual For Optional Items

    COMCO IKARUS Maintenance Manual C42 Series 2.1.2 Installation manual for Optional Items 2.1.2.1 Cowl Flap C42 Serie / C52 I. General: Cowl flap for C42B/C and C52 allows to considerably shorten warm-up period of the engine and to keep oil cylinder head temperature during flight operations in optimal range of 90-110°C.
  • Page 18 COMCO IKARUS Maintenance Manual C42 Series - Assemble lower cowling, push the Bowden cable through the cut slot, lay it upward and push through the central firewall aperture. Figure 9: Bowden cable - Secure the Bowden cable with cable ties against contact with hot exhaust parts.
  • Page 19 COMCO IKARUS Maintenance Manual C42 Series - After functionality test secure the Bowden cable with cable and sleeve and shrink tubing and cut off the supernatant Bowden cable. III. Electrical Installation: - Dismantel free temperature sensor at the front left cylinder.

  • Page 20: Sources For Spare Parts

    - Assembling can be carried out in reversed order. 2.1.3 Sources for Spare parts Spare parts for the C42 Series can be obtained from the following sources :- All IFCs / ITB / ISC (Comco Ikarus distributor) look at our website http://www.comco- ikarus.de...

  • Page 21: Recommended Stocking List

    COMCO IKARUS Maintenance Manual C42 Series 2.1.5 Recommended Stocking List Description Set brake discs Complete set brake pads Tyres Inner tubes Suspension air pump Metric socket set Metric allen key set Litre LHM fluid Nose wheel axle Front forks Square tube...

  • Page 22: Weight & Balance

    COMCO IKARUS Maintenance Manual C42 Series 2.2 Weight & Balance The aircraft should be maintained in a configuration which meets the weight and balance criteria set out below and in the P.O.H.. If you are unsure of which certification you are flying under please refer to the P.O.H.

  • Page 23: Conditions Of Weighing

    COMCO IKARUS Maintenance Manual C42 Series Insert the values for total empty weight, (G1 + G2) and cg distance aft of datum, (X), into the table below. Multiply Empty Weight (kg) by cg distance aft of datum (mm) to derive empty weight moment (kg.mm) in the last column.

  • Page 24: Design

    COMCO IKARUS Maintenance Manual C42 Series 2.3 Design The fuselage, wings, struts and empennage are made of high-strength aluminium tubing/sections. The parts are screwed, riveted or welded to each other. All fittings and screws are either made from stainless steel or are high-strength standard elements.
  • Page 25 COMCO IKARUS Maintenance Manual C42 Series veritical tail rudder empennage strut horizontal tail elevator trim elevator Figure 17: Empennage design Non-supporting glass fibre/carbon fibre elements, partially in sandwich design, are used for the fuselage shell and the skin. The covering is made of a UV-stabilised webbed fabric (brand name: Tedlar®).

  • Page 26: Landing Gear

    COMCO IKARUS Maintenance Manual C42 Series 2.4 Landing gear Nose wheel landing gear: The nose wheel landing gear comprises the sprung nose wheel fork, the axle bolt, the nose wheel, the nose wheel spar and the steering bar. Up until 2003, a steel compression spring was used.

  • Page 27: Power Plants

    2.5 Power plants 2.5.1 Difference between C42 / C42 UK and C42B / C42B UK / C42E: Since production year 2002, COMCO IKARUS has also been offering the C42B / C42B UK / C42E, a further developed model. The differences between the C42 / C42 UK and the C42B / C42B UK / C42E are to be found in the engine compartment.
  • Page 28 COMCO IKARUS Maintenance Manual C42 Series Figure 21: Rotax 912UL engine (C42B / C42B UK / C42E) MaintenanceManual C42- Revison No.:1 24 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 29: Air Induction System

    COMCO IKARUS Maintenance Manual C42 Series 2.5.3 Air induction system: the case of the C42 / C42 UK air is drawn in through the air filters mounted inside the engine compartment. In the case of the C42B / C42B UK / C42E, ambient air is drawn in through an inlet in the cowling and fed to the carburettors.

  • Page 30: Cooling System

    COMCO IKARUS Maintenance Manual C42 Series 2.5.4 Cooling system: The cylinder heads of the Rotax 912UL engine are liquid-cooled whereas the cylinder barrels are air-cooled. In the case of the C42 / C42 UK, there are separate cooling systems for the coolant and the oil.

  • Page 31: Propeller

    More details about the propellers and the appropriate maintenance measures are to be found in the relevant propeller documents or are available directly from COMCO IKARUS GmbH . 2.5.6 Exhaust system: The exhaust system manufactured by Heggemann is made of stainless steel components and is attached elastically to the engine by means of tension springs and ball cup connections.

  • Page 32: Fuel System

    COMCO IKARUS Maintenance Manual C42 Series 2.6 Fuel system tank filler fuel level sensor firewall right and left carburettor tank ventilation fuel valve tank electrical fuel pump T fitting fuel filter fuel tank sump mechanical drainage valve fuel pump electrical fuel pump...
  • Page 33 COMCO IKARUS Maintenance Manual C42 Series tank ventilation tank filler fuel filter fuel level sensor T fitting with restriction valve flow sensor for CAT electrical fuel fuel computer (optional pump equipment) electrical fuel pump by-pass mechanical fuel valve fuel pump...
  • Page 34 COMCO IKARUS Maintenance Manual C42 Series Vent tube Fuel gauge sender Filler nozzle Vapour return tube Fuel tank components Electric fuel pump & Andair check valve Electric fuel pump Andair check valve Electric fuel pump by-pass pipe Figure 30: Fuel system components C42 UK / C42B UK / C42E MaintenanceManual C42- Revison No.:1...

  • Page 35: Electrical System

    COMCO IKARUS Maintenance Manual C42 Series 2.7 Electrical system The C42 is supplied with electricity via a generator attached to the engine (cf. Rotax documentation). Together with a regulator-rectifier, it provides 12.5 - 14.2 V DC voltage to the aircraft electrical system and simultaneously charges the battery. In aircraft with a ballistic recovery system, the battery is located on the underside of the fuselage tube near the seats.
  • Page 36 Maintenance of the electrical system is in accordance with the Inspection schedule in Section 1 – Inspections. All defective electrical components must be replaced with new parts obtained only from IFC / ISC ( COMCO IKARUS distributor ) Regulator / rectifier Earthing points...
  • Page 37 COMCO IKARUS Maintenance Manual C42 Series Regulator / rectifier Earthing points Starter motor solenoid Figure 34: Electrical parts (new regulator since 2008 ) MaintenanceManual C42- Revison No.:1 33 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 38: Flight Controls

    COMCO IKARUS Maintenance Manual C42 Series 2.8 Flight controls The flight controls and the wing flaps of the C42 are actuated by push-rods, torsion tubes and cables. 2.8.1 Elevator: The elevator is actuated via the control stick and two push-rods. Actuation direction is reversed by means of a bellcrank on top of the fuselage tube.

  • Page 39: Aileron

    COMCO IKARUS Maintenance Manual C42 Series trim tab control horn trim servo underneath the covering Figure 37: Activation of the electrical trim tab 2.8.3 Aileron: The control stick is attached to a torsion tube. This torsion tube drives two cables via a bellcrank.

  • Page 40: Rudder

    COMCO IKARUS Maintenance Manual C42 Series 2.8.4 Rudder: The rudder is actuated via floor pedals which are attached to torsion tubes which run in journal bearings directly mounted to the fuselage tube. The torsion tubes are connected to the rudder control horn via cables / Bowden cables routed along the fuselage tube.
  • Page 41 COMCO IKARUS Maintenance Manual C42 Series Figure 41: Nose wheel steering system C42 UK / C42B UK / C42E Figure 42:Rudder return cable & spring for C42B UK / C42 E Attention! As from December 2009, all C42 aircraft are equipped with the new pedals.

  • Page 42: Wing Flaps

    COMCO IKARUS Maintenance Manual C42 Series 2.8.6 Wing flaps: The wing flaps are actuated by a lever located in the middle of the longitudinal tube of the canopy roof frame. The lever is linked to the flap horns via push-rods.

  • Page 43: Carburettor Control

    COMCO IKARUS Maintenance Manual C42 Series 2.8.7 Carburettor control The throttle is controlled by 2 throttle levers via Bowden cables. The choke is also actuated via a central pull-knob and Bowden cables. throttle throttle valve Bowden cable choke choke Bowden...

  • Page 44: Brakes

    A better-quality wheel is part of this optional equipment which offers better impact damping and a much longer service life. Retro-fit kits will be available from February 2010 from COMCO IKARUS GmbH and can be ordered from the IFC / ISC.
  • Page 45 COMCO IKARUS Maintenance Manual C42 Series brake tubing brake disc brake shoe Brake lever with integrated retention bolt master brake cylinder brake pad Figure 47: Brake system – "Magura-BIG" brakes (since 06/2003) brake shoe brake tubing brake disc Figure 48: Brake system – "Behringer" brakes (optional, from 01/2010) MaintenanceManual C42- Revison No.:1...
  • Page 46 COMCO IKARUS Maintenance Manual C42 Series brake disc brake shoe Brake lever with integrated brake tubing master brake cylinder Abbildung 49: Brake system – “Tost“ brakes (optional from 11/2010 ) MaintenanceManual C42- Revison No.:1 42 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 47: Instruments

    Cylinder head temperature indicator Fuel tank indicator Further instruments are available on request. For further information on operation and maintenance, please consult the documents relevant to the appropriate instrument or contact an IFC / ISC or COMCO IKARUS GmbH. MaintenanceManual C42- Revison No.:1 43 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 48: Heating

    COMCO IKARUS Maintenance Manual C42 Series 2.10 Heating Cabin heating is part of the standard equipment of the C42 / C42B / C42 UK / C42B UK / C42E : control knob heating valve heating hose in the cockpit firewall...

  • Page 49: Cleaning And Care

    COMCO IKARUS Maintenance Manual C42 Series 3 Cleaning and care 3.1 Aircraft covering Soiled aircraft covering can usually be easily removed with water. More persistent dirt may be removed at a suitable place (environmental protection) by car shampoo or detergent. While cleaning the covering, it can also be checked for damage to the skin and the integrity of the seams.

  • Page 50: Metal Parts

    Maintenance Manual C42 Series 3.4 Metal parts All metal parts of the Ikarus C42 are protected against corrosion and thus do not require special care. Should parts become dirty, they can be cleaned using normal metal cleaning agents. A thin wax or grease film on the electro-galvanised steel parts increases corrosion protection, particularly in older aircraft.
  • Page 51 COMCO IKARUS Maintenance Manual C42 Series The following connections should be treated regularly: rod ends on the torsion tube under the control stick. − rod ends on both elevator push-rods − brass bushing in the torsion tube, directly under the control stick −...

  • Page 52: Servicing The C42

    4.1 General maintenance information This chapter contains all the important information and regulations concerning the handling and maintenance of the Ikarus C42. It is essential that you read this chapter before undertaking any maintenance or repair work. 4.1.1 Safety elements As customary in aircraft manufacturing, all connections in the C42 are safetied in one way or another.
  • Page 53 COMCO IKARUS Maintenance Manual C42 Series Since screws and nuts, and particularly those made of stainless steel tend − to stick, machinery grease must be used during assembly. At least two turns of thread of the screw must be visible outside the nut to −...

  • Page 54: Welded Joints

    COMCO IKARUS Maintenance Manual C42 Series 4.1.3 Welded joints There are relatively few welded joints in the C42. For example, the canopy roof frame is a welded aluminium structure. Further welded connections are to be found on the elevator control horn and the wing root rib.

  • Page 55: Rivet Connections

    COMCO IKARUS Maintenance Manual C42 Series 4.1.4 Rivet connections Many of the permanent connections in the C42 take the form of rivet connections. This is particularly the case in the fuselage tube, engine mount and cross beam. Here, mainly special blind rivets (e.g. Magna Bulb - brand name) are used.

  • Page 56: Propeller

    COMCO IKARUS Maintenance Manual C42 Series 4.1.5 Propeller Any defect propeller parts must be replaced by new parts. Only original spare parts may be used. In the case of composite propellers, even slight damage to the surface can have grave effects on strength properties and thus safety. If cracks go deeper than the outer surface, propeller strength is reduced and humidity can seep into the structure which can result in propeller imbalance.
  • Page 57 COMCO IKARUS Maintenance Manual C42 Series Left wing: 1. Check that the wing spar connections are secure 2. Check that wing struts are properly connected and secure. 3. Check that auxiliary struts with quick-release fasteners are secure 4. Check that airspeed indicator pick-up is secure, free from dirt and water and pulled out 5.
  • Page 58 COMCO IKARUS Maintenance Manual C42 Series Cockpit: 1. Check condition of windscreens and doors, including the locks (cracking) 2. Check controls for freedom of movement (control stick, pedals, wing flap lever and detent) 3. Check brake lever and standard detent 4.

  • Page 59: Periodic Inspections

    COMCO IKARUS Maintenance Manual C42 Series 4.2.1 Periodic inspections Aircraft type: ____________________ Date of inspection: _______________ Call-sign: ____________________ Serial no.: _______________ No. of flight hours ____________________ Inspection Ref. Description Signature Chapter every very hours hours Clean the aircraft Engine cowling Check condition of engine cowling and its attachments;...
  • Page 60 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Induction system Check condition and attachment of the induction system hoses (C42 B / E only) and air filter attachment (C42 A), respectively Check condition of air filters and clean as required...
  • Page 61 (silver aluminium tube under the instrument panel) for deformation, proper attachment and condition Check condition and functionality of heating valve Propeller Service according to the relevant instructions from COMCO IKARUS in accordance with COMCO IKARUS GmbH GmbH instructions...
  • Page 62 Check propeller clearance (ground, cowling) Check propeller pitch control mechanism in accordance with COMCO in accordance with COMCO IKARUS IKARUS GmbH instructions (only if a variable pitch propeller is GmbH instructions installed) Nose wheel landing gear Check nose gear fairing for secure fitting and damage; repair or...
  • Page 63 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Main landing gear Check main landing gear fairing for secure fitting and damage; repair or replace as required Check wheel pants and wheel pant brackets for secure fitting and damage;...
  • Page 64 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Check brake discs for wear and true running; replace as required Wing Check wing tips/winglets for damage; repair or replace as required Visual inspection of covering for any kind of damage and integrity of seams;...
  • Page 65 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Clean, grease and secure rod ends and check for play Check security of aileron push-rods short/long 4.3.5.2 Check quick-release fittings of the aileron push-rods at the aileron...
  • Page 66 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Fuselage Frame Check metal frame (fuselage tube, A/B/C columns, canopy roof frame, struts, fittings, etc.): - screw connections - rivet connections - welded connections - joints...
  • Page 67 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Check condition and functionality of cabin locks Check condition and functionality of ventilation window Empennage Horizontal tail Check condition of horizontal tail struts and for secure fitting...
  • Page 68 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Electrical trim tab Check functionality and the connections for secure fitting (insofar as they are accessible, cf. circuit diagram) Mechanical trim tab Check function, condition and attachment of the Bowden cable; if stiff,...
  • Page 69 COMCO IKARUS Maintenance Manual C42 Series Inspection Ref. Description Signature Chapter every very hours hours Flight controls Check control stick attachment Check control stick for freedom of movement Check throttle for freedom of movement and sufficient friction 4.3.6.4 Check Bowden cables for freedom of movement; grease if necessary...

  • Page 70: Maintenance Instructions

    COMCO IKARUS Maintenance Manual C42 Series 4.3 Maintenance instructions 4.3.1 Engine compartment 4.3.1.1 Synchronising the carburettors Synchronising the carburettors may either be done by pneumatic synchronising or by mechanical synchronising. For pneumatic synchronising two manometers are required. No special tools are required for mechanical synchronising.

  • Page 71: Inspection Of Air Hoses Between The Carburettors And The Air Filters

    COMCO IKARUS Maintenance Manual C42 Series 4.3.1.2 Inspection of air hoses between the carburettors and the air filters The pressure sensor hoses must be checked for damage, general condition and secure fitting. pressure sensor tubes C42 /C42 UK C42B / C42B UK / C42E...

  • Page 72: Fuel System

    COMCO IKARUS Maintenance Manual C42 Series 4.3.2 Fuel system 4.3.2.1 Checking cleanliness in the fuel tank First, the tank must be emptied. With the help of a torch, the tank is then screened from the outside. Dirt usually collects in the sump. If contamination is found, the tank can be washed out with methylated spirits.

  • Page 73: Landing Gear

    COMCO IKARUS Maintenance Manual C42 Series 4.3.3 Landing gear 4.3.3.1 Greasing the nose wheel fork bearing The nose wheel fork bearing in the nose wheel spar must be greased. Using a grease gun, grease is pressed in via the grease nipples above and below the nose wheel spar.

  • Page 74: Brakes

    COMCO IKARUS Maintenance Manual C42 Series 4.3.4 Brakes brake line brake disc safety ring fixation lever brake shoe setting screw brake pad cotter bolt Figure 62: Brakes 4.3.4.1 Replenishing brake fluid 1) Remove safety ring from brake lever, pull out the cotter bolt and remove the brake lever.
  • Page 75 COMCO IKARUS Maintenance Manual C42 Series 3) Carefully pull out the pressure piston using long nose pliers. Be careful not to damage the grey sealing ring. Figure 64: Removing the pressure piston 4) Using a syringe (e.g. from the chemist) or a pipette, fill in Magura brake fluid (available form IFC / ISC), until the correct filling level is reached (approx.

  • Page 76: Changing The Brake Pads

    The brake discs of the C42 are riveted to the rims by means of an adapter. The rivets can only be removed or set anew using special tools. For this reason, damaged brake discs should always be replaced by an IFC / ISC or by COMCO IKARUS GmbH.

  • Page 77: Wing

    COMCO IKARUS Maintenance Manual C42 Series 4.3.5 Wing 4.3.5.1 Inspecting and replacing wing battens Open the zip in the covering and carry out a visual inspection of the batten connections to the wing tubes. Pay particular attention to damage to the eccentric spanner of the upper battens on the rear wing tube.
  • Page 78 COMCO IKARUS Maintenance Manual C42 Series 2) Remove batten safety plate by bending it up. A new plate is delivered with a new batten. eccentric spanner batten safety plate upper / lower batten rear wing tube Figure 67: Batten safety plate Pull out the lower batten.

  • Page 79: Checking The Security Of The Aileron Push-Rods

    COMCO IKARUS Maintenance Manual C42 Series Flattened Do not flatten in safety plate plane bending. The plate could flattening the otherwise break. safety plate Figure 68: Flattening the safety plate 12) Clean and degrease the covering where the masking tape is attached.

  • Page 80: Flight Controls

    If this is not the case, an IFC / ISC or COMCO IKARUS GmbH must be contacted. Adjustments...

  • Page 81: Servicing The Elevator Reversal Bellcrank

    COMCO IKARUS Maintenance Manual C42 Series 4.3.6.3 Servicing the elevator reversal bellcrank The following areas in particular must be inspected carefully: the bracket of the elevator reversal bellcrank for cracks, the rivet connection for proper fit and missing rivets , the screws at the bracket for proper fit and condition.

  • Page 82: Visual Inspection Of The Empennage Attachment Safety Screws

    COMCO IKARUS Maintenance Manual C42 Series 4.3.7 Visual inspection of the empennage attachment safety screws The inspection can be carried out through the baggage bin and using a torch and comprises checking that none of the horizontal tail fin attachment safety screws is missing.

  • Page 83: Inspecting The Pitot-Static Pressure System

    COMCO IKARUS Maintenance Manual C42 Series 4.3.8 Inspecting the pitot-static pressure system This inspection can be carried out with special measuring equipment. If such equipment is not available, the inspection may be undertaken using simpler means. The inspection is carried out by two people. A clean and leak-proof injection syringe and a short piece of appropriate and elastic tubing (inner diameter 5 mm) are needed.

  • Page 84: Static Pressure System

    COMCO IKARUS Maintenance Manual C42 Series 4.3.8.2 Static pressure system Static pressure is picked up inside the fuselage beneath the wing tube close to the elevator reversal bellcrank. fuselage tube static pressure system tube (tube end and U attached by a clip)

  • Page 85: Repairing The C42

    (see above). Large cracks: The covering must be removed and sent to an IFC / ISC or COMCO IKARUS GmbH if cracks are larger than 25 cm. Entire stretches can then be made by sail makers, as required.

  • Page 86: Damage To The Seams

    Be careful not to damage the covering. The affected position can then be patched. If the damage is greater (> 1 cm) an IFC / ISC or COMCO IKARUS GmbH must be contacted.

  • Page 87: Fuselage

    COMCO IKARUS Maintenance Manual C42 Series 5.2.1 Fuselage A 165 mm diameter aluminium tube runs from nose to tail and carries all the major assemblies: engine, seats, undercarriage, fuel tank, and tail empennage. cockpit structure, consisting of a thin walled aluminium tube frame, includes a welded aluminium box-section frame at its top to which the wing spars’...

  • Page 88: Wing

    COMCO IKARUS Maintenance Manual C42 Series 5.2.2 Wing The wing has a ladder construction comprising leading and trailing edge tubes, connected by compression struts at intervals along its span. The triangulated wing struts, terminating at a fixed point at the top of the undercarriage, brace the wing against fore and aft loads.

  • Page 89: Rigging The Wings

    COMCO IKARUS Maintenance Manual C42 Series 5.2.3 Rigging the Wings Before attempting rigging, take a look at the wing roots and the way in which the rigging mechanism works. Note that the fulcrum (the roller bracket) is located near the wing root, and also in line with the rear spar attachment point. The front spar attachment point however is located some way inboard.
  • Page 90 COMCO IKARUS Maintenance Manual C42 Series Step 13. Connect the pitot tube to its fitting situated to the left of the pilot’s headrest. Pull out the pitot tube forwards to its full extent. Step 14. Repeat steps 1 through 12 for the other wing. Now you may remove the control lock.
  • Page 91 COMCO IKARUS Maintenance Manual C42 Series Wing fwd spar Fwd spar attachment bracket Figure 80: Fwd spar attachment Aft spar attachment bracket Figure 81: Aft spar attachment MaintenanceManual C42- Revison No.:1 87 from 107 Series_Issue_VII_18.02.2014.doc...
  • Page 92 COMCO IKARUS Maintenance Manual C42 Series Aileron pushrods attached to bell crank Figure 82: Aileron attachment Flap driver attachment point Figure 83: Flap attachment MaintenanceManual C42- Revison No.:1 88 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 93: Undercarriage

    COMCO IKARUS Maintenance Manual C42 Series 5.2.4 Undercarriage The tricycle undercarriage has suspension on all wheels and damping on the main wheels. The front fork is directly connected to the rudder pedals. Hydraulic disc brakes operate on the main wheels only.

  • Page 94: Landing Gear

    COMCO IKARUS Maintenance Manual C42 Series 5.2.5 Landing gear 5.2.5.1 Jacking up the aircraft In order to carry out various maintenance measures on the landing gear, the aircraft must be jacked up. The following instructions should be followed to this end: Nose wheel landing gear: The nose wheel landing gear can be raised by weighing down the tail of the C42.

  • Page 95: Repairing Rivet Connections

    COMCO IKARUS Maintenance Manual C42 Series 5.3 Repairing rivet connections It must be ensured that the correct type of rivet is used and mounted in the proper way (cf. Chapter 4.1.4). If rivets come loose due to exceptional loading, or if a riveted component has to be replaced, the following procedure should be followed: 1.

  • Page 96: Repairing The Glass-Fibre / Carbon-Fibre Skins

    COMCO IKARUS Maintenance Manual C42 Series 5.5 Repairing the glass-fibre / carbon-fibre skins In contrast to many sailplanes and other micro-light aircraft, the glass-fibre/carbon- fibre parts of the C42 rarely carry loads as they are mainly fairings. Damage to glass-fibre/carbon-fibre parts thus has no effect on the strength of the aircraft. This is also the reason repair work on the glass-fibre/carbon-fibre parts of the C42 is relatively simple.

  • Page 97: Electrical Repairs

    5.6 Electrical repairs Faulty electrical components may only be replaced by new original spare parts which may be ordered from an IFC / ISC or directly from COMCO IKARUS., Circuit diagrams are to be found in the appendix to this manual.

  • Page 98: Appendix

    COMCO IKARUS Maintenance Manual C42 Series 6 Appendix 6.1 Operating fluids 6.1.1 Engine oil Exact details concerning oil type and amount are given in the Rotax documents. 6.1.2 Coolant The coolant used must be suitable for aluminium engines and must not be mixed.

  • Page 99: Control Surface Deflections

    COMCO IKARUS Maintenance Manual C42 Series 6.2.3 Control surface deflections Note: The basic setting of the ailerons is 7° relative to airfoil chord (tangent front to rear spar). It is defined by the length of the aileron push-rods. -7° distance from axis of rotation Aileron 20°...

  • Page 100: Recommenden Fasterner Torque Values

    COMCO IKARUS Maintenance Manual C42 Series 6.2.5 Recommenden fasterner torque values Refer to rotax manual torque moment, torque moment, Type of propeller propeller attachment screws propeller blade clamping screws WarpDrive 25 Nm 12 – 15 Nm 2 blade / 3 blade Sportprop ø170...
  • Page 101 COMCO IKARUS Maintenance Manual C42 Series Wing torque settings MaintenanceManual C42- Revison No.:1 97 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 102: Placards

    COMCO IKARUS Maintenance Manual C42 Series 6.3 Placards Subject Location aerobatic warning instrument panel trim canopy roof frame wing flaps, mechanical canopy roof frame engine oil specifications oil inspection cover fuel specifications tank filler baggage loading baggage bin cover deviation chart...

  • Page 103: Notification Of Technical Defect And/Or Damage To Micro-Light Aircraft

    COMCO IKARUS Maintenance Manual C42 Series 6.4 Notification of technical defect and/or damage to micro-light aircraft Type of micro-light: _______________ Serial no.: __________________ Year of construction: _______________ Engine: __________________ COMCO IKARUS GmbH: __________________________________________ Owner: _______________________________________________ Registration: _______________________________________________ No. of flight hours when damage/defect occurred:________________________...

  • Page 104: Circuit Diagrams

    COMCO IKARUS Maintenance Manual C42 Series 6.5 Circuit Diagrams 6.5.1 Circuit Diagram until Nov. 2008 MaintenanceManual C42- Revison No.:1 100 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 105: Circuit Diagram Until Nov. 2008

    COMCO IKARUS Maintenance Manual C42 Series 6.5.2 Circuit Diagram until Nov. 2008 MaintenanceManual C42- Revison No.:1 101 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 106: Circuit Diagram Since Nov. 2008

    COMCO IKARUS Maintenance Manual C42 Series 6.5.3 Circuit Diagram since Nov. 2008 MaintenanceManual C42- Revison No.:1 102 from 107 Series_Issue_VII_18.02.2014.doc...

  • Page 107: Circuit Diagram Electric Trim

    COMCO IKARUS Maintenance Manual C42 Series 6.5.4 Circuit Diagram Electric Trim MaintenanceManual C42- Revison No.:1 103 from 107 Series_Issue_VII_18.02.2014.doc...

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