iKarus C42 User manual

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

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Disclaimer of liability
1. Maintenance manual content
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
information provided or by the usage of any incorrect of incomplete information
are generally excluded unless wilful or gross negligence can be proven against
COMCO IKARUS.
All information is non-binding and without obligation. COMCO IKARUS retains
the right to modify, supplement or delete any parts of this manual, or the entire
manual, or temporarily or permanently cease its publication.
2. Copyright and flag right
COMCO IKARUS endeavours in all its publications to respect the copyright of
any images, graphics and texts used belonging to a third party. It also aims at
using images, graphics and texts for which it has the copyright or which are
royalty-free.
All third party brand marks and trademarks named in this manual underlie the
regulations of the valid trademark and ownership law for each registered owner.
The simple usage of a brand name does not mean that a third party does not
protect the rights to that name!
The copyright for all objects created and published by COMCO IKARUS
remains solely by COMCO IKARUS. Duplication or utilisation of such graphics
and texts in other electronic or printed publications is prohibited unless COMCO
IKARUS has granted its explicit consent.
3. Legal force of this disclaimer
This disclaimer is part of the maintenance manual. If any parts or individual
formulations of this text should fail to conform to the valid legal situation, or be
no longer or not fully in conformity therewith, this shall not affect the content or
validity of the remaining parts of the document.

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The illustrations in this maintenance manual depict one or several typical
designs. It is possible that they do not conform in every detail or in form with the
actual part. 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.
COMCO IKARUS retains the right to modify specifications, designs, details,
models or equipment at any time, but without any commitment.
All technical data and information in this manual are the property of COMCO
IKARUS GmbH. Without prior written permission from COMCO IKARUS
GmbH, it is not allowed to copy this manual partially or completely or pass it on
to any third parties.
Should COMCO IKARUS grant written permission to partially or completely
copy this manual, this text must appear on every partial or complete
reproduction.

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Log of revisions
No. Change Page Issue Date Signature
1 Brake 21 - 22 Issue II Dec. 2010 A.Kurz
2 Picture 46 u. 56 Issue II Dec. 2010 A.Kurz
3 Appendix 6: 6.2.3 Brake fluids 67 Issue II Jan. 2011 A.Kurz
4 Berichtigungsstand Page III Issue II April 2011 A.Kurz
5 Revisionsnummer eingetragen All Issue III 20 Mai 2011 A.Kurz
6 Picture LSA 16 / 19 Issue IV 07 July 2011 A.Kurz
7 All documents revised All Issue V 08 August.2011 A.Kurz
8 Installation manual Cowl flap 12 Issue VI 15 July 2012 A.Kurz
- Pics C42C 8 Issue VI 15 July 2012 A.Kurz
- Three-view C42C 10 Issue VI 15 July 2012 A.Kurz
9 25 Hour Inspection delete 5 / 55-65 Issue VII 08 July 2013 A.Kurz
10 Incorporated Periodic checks
between point 44 and 45 Note
Kapitel
4.2.1 Issue VII Rev. 1 18.February 2014 A.Kurz
- Entered revision number All -- -- --

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Table of Contents
1 Introduction ............................................................................................... 5
1.1 Overview on maintenance..................................................................................... 5
1.2 Carrying out maintenance work ........................................................................... 6
2 Technical description ............................................................................... 7
2.1 Equipment List......................................................................................................11
2.1.1 Optional Items.................................................................................................................. 12
2.1.2 Installation manual for Optional Items ............................................................................. 13
2.1.2.1 Cowl Flap C42 Serie / C52 ..................................................................................... 13
2.1.3 Sources for Spare parts................................................................................................... 16
2.1.4 Consumable items ........................................................................................................... 16
2.1.5 Recommended Stocking List ........................................................................................... 17
2.2 Weight & Balance .................................................................................................18
2.2.1 Weight and Balance Calculations .................................................................................... 18
2.2.2 Conditions of Weighing.................................................................................................... 19
2.3 Design ...................................................................................................................20
2.4 Landing gear.........................................................................................................22
2.4.1 Main landing gear: ........................................................................................................... 22
2.5 Power plants .........................................................................................................23
2.5.1 Difference between C42 / C42 UK and C42B / C42B UK / C42E: .................................. 23
2.5.2 Engine:............................................................................................................................. 23
2.5.3 Air induction system:........................................................................................................ 25
2.5.4 Cooling system: ............................................................................................................... 26
2.5.5 Propeller:.......................................................................................................................... 27
2.5.6 Exhaust system:............................................................................................................... 27
2.6 Fuel system...........................................................................................................28
2.7 Electrical system ..................................................................................................31
2.8 Flight controls.......................................................................................................34
2.8.1 Elevator:........................................................................................................................... 34
2.8.2 Trim:................................................................................................................................. 34
2.8.3 Aileron:............................................................................................................................. 35
2.8.4 Rudder: ............................................................................................................................ 36
2.8.5 Nose gear steering: ......................................................................................................... 36
2.8.6 Wing flaps: ....................................................................................................................... 38
2.8.7 Carburettor control........................................................................................................... 39
2.8.8 Brakes:............................................................................................................................. 40
2.9 Instruments...........................................................................................................43
2.10 Heating ................................................................................................................44
3 Cleaning and care ................................................................................... 45
3.1 Aircraft covering...................................................................................................45
3.2 Windscreens .........................................................................................................45
3.3 Glass-fibre components.......................................................................................45
3.4 Metal parts.............................................................................................................46

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3.5 Cockpit and instruments......................................................................................46
3.6 Movable connections, particularly in the flight controls ...................................46
4 Servicing the C42.................................................................................... 48
4.1 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 Rivet connections ............................................................................................................ 51
4.1.5 Propeller........................................................................................................................... 52
4.2 Pre-flight check.....................................................................................................52
4.2.1 Periodic inspections......................................................................................................... 55
4.3 Maintenance instructions.....................................................................................66
4.3.1 Engine compartment........................................................................................................ 66
4.3.1.1 Synchronising the carburettors............................................................................... 66
4.3.1.2 Inspection of air hoses between the carburettors and the air filters....................... 67
4.3.2 Fuel system...................................................................................................................... 68
4.3.2.1 Checking cleanliness in the fuel tank ..................................................................... 68
4.3.2.2 Checking the electrical fuel pump........................................................................... 68
4.3.3 Landing gear .................................................................................................................... 69
4.3.3.1 Greasing the nose wheel fork bearing.................................................................... 69
4.3.3.2 Checking and setting the shock absorbers............................................................. 69
4.3.4 Brakes.............................................................................................................................. 70
4.3.4.1 Replenishing brake fluid ......................................................................................... 70
4.3.4.2 Changing the brake pads........................................................................................ 72
4.3.4.3 Changing the brake discs ....................................................................................... 72
4.3.5 Wing................................................................................................................................. 73
4.3.5.1 Inspecting and replacing wing battens ................................................................... 73
4.3.5.2 Checking the security of the aileron push-rods ...................................................... 75
4.3.6 Flight controls................................................................................................................... 76
4.3.6.1 Adjusting the cable tension of the aileron control system ...................................... 76
4.3.6.2 Checking the connection of the sliding sleeve with the flap spar ........................... 76
4.3.6.3 Servicing the elevator reversal bellcrank................................................................ 77
4.3.6.4 Setting the throttle friction ....................................................................................... 77
4.3.7 Visual inspection of the empennage attachment safety screws...................................... 78
4.3.8 Inspecting the pitot-static pressure system ..................................................................... 79
4.3.8.1 Pitot pressure system: ............................................................................................ 79
4.3.8.2 Static pressure system ........................................................................................... 80
5 Repairing the C42 ................................................................................... 81
5.1 Repairing the covering.........................................................................................81
5.1.1 Damage to the fabric ....................................................................................................... 81
5.1.2 Damage to the seams...................................................................................................... 82
5.1.3 Thermal tensioning of the covering.................................................................................. 82
5.2 Repairing the aircraft structure ...........................................................................82
5.2.1 Fuselage .......................................................................................................................... 83
5.2.2 Wing................................................................................................................................. 84
5.2.3 Rigging the Wings............................................................................................................ 85
5.2.4 Undercarriage .................................................................................................................. 89
5.2.5 Landing gear .................................................................................................................... 90
5.2.5.1 Jacking up the aircraft............................................................................................. 90
5.3 Repairing rivet connections.................................................................................91
5.4 Glass repairs.........................................................................................................91

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5.5 Repairing the glass-fibre / carbon-fibre skins ....................................................92
5.6 Electrical repairs...................................................................................................93
5.7 Ikarus Flight Centres ............................................................................................93
6 Appendix.................................................................................................. 94
6.1 Operating fluids ....................................................................................................94
6.1.1 Engine oil ......................................................................................................................... 94
6.1.2 Coolant............................................................................................................................. 94
6.1.3 Brake fluid ........................................................................................................................ 94
6.2 Settings .................................................................................................................94
6.2.1 Angle of incidence wing - fuselage tube .......................................................................... 94
6.2.2 Angle of incidence horizontal tail fin - fuselage tube ....................................................... 94
6.2.3 Control surface deflections .............................................................................................. 95
6.2.4 Tyre pressure................................................................................................................... 95
6.2.5 Recommenden fasterner torque values .......................................................................... 96
6.3 Placards ................................................................................................................98
6.4 Notification of technical defect and/or damage to micro-light aircraft .............99
6.5 Circuit Diagrams.................................................................................................100
6.5.1 Circuit Diagram until Nov. 2008 ..................................................................................... 100
6.5.2 Circuit Diagram until Nov. 2008 ..................................................................................... 101
6.5.3 Circuit Diagram since Nov. 2008 ................................................................................... 102
6.5.4 Circuit Diagram Electric Trim ......................................................................................... 103

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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.
The sophisticated and robust construction of the aircraft combines easy maintenance
and repair work with solid flight performance and above-average flight
characteristics.
Its versatility allows universal utilisation in various fields of activity. The C42 is a
recognised training and towing aircraft, it allows stress-free and comfortable travel
and can be used for special missions such as parachute jumping, as a seaplane or a
crop duster or, with skis attached, land on snow without difficulty.
The reliable global spare parts supply and 24 hour delivery within Germany is
exemplary. This means that you or an Ikarus Flight Centre (IFC) / Ikarus Service
Centre (ISC) can carry out maintenance or repair work on the C42 quickly and easily.
This maintenance manual serves as a guideline for the implementation of
maintenance measures. In addition, it is hoped that technically interested owners will
be given an insight into the design and maintenance of the C42 and thus be able to
make a contribution to flight safety and maintaining the value of their aircraft.

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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. The following inspections are scheduled for the C42:
−every 50 hours
−every 100 hours
Before every flight, a pre-flight check must be carried out by the pilot.
In the case of damage caused by a hard landing or a collision with obstacles, special
inspections and repair work must be carried out.
These measures have been developed to ensure that the aircraft remains airworthy
over a longer period of time, that wear and tear is minimised and that the C42 has a
long service life.
Experience shows that regular care and maintenance exceeding the levels required
by the inspections results in a good, clean and well-performing aircraft. Defects and
damage are more readily detected if the aircraft is regularly cared for and cleaned.

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1.2 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.
Contact details can be found on our web site www.comco-ikarus.de. These centres
have competent staff who are qualified in the maintenance and repair of the Ikarus
C42.
In addition, technically adept owners may carry out maintenance work on the C42.
Should repair work be necessary, the owner is restricted to work involving the
exchanging of defect parts. If the owner carries out maintenance and repair work
himself, such work must be done carefully and in accordance with the instructions
given in this manual.
Original spare parts must be used. They are available in the IFC / ISC or directly from
COMCO IKARUS.
The alteration of individual components or the use of spare parts which are not
originals is not permitted. Under no circumstances may parts be worked off,
straightened or repaired in any way. This can lead to aircraft impairment which, in
turn, may lead to life-threatening accidents.
Major technical faults or defects must be reported to COMCO IKARUS GmbH or the
appropriate national authority. In Germany, the competent authority is:
Luftsportgerätebüro des DAeC
In Germany, airworthiness inspections are carried out by DAeC-approved Class V
inspectors. Please check the rules and regulations in the country in which your C42
is registered.

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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.
Figure 1: Ikarus C42 / C42 UK
Figure 2: Ikarus C42B / C42B UK / C42E

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Figure 3: Ikarus C42C

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Figure 4: Three-view Ikarus C42 / C42 UK
Figure 5: Three-view C42B / C42 B UK/ C42E

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Figure 6: Three-view C42C

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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.
Wings and empennage are covered with lattice cloth foil
(GT-foil) with high tensile strength and UV treated.
All fairings in glass-fibre/epoxy resin and Kevlar Aramid
Honeycomb.
Cabin windshields made of Makrolon.
Removable wings.
Power Plant: 4 cylinder, 4-stroke liquid-cooled / air-cooled Rotax 912 UL
boxer motor 58 kW/80 hp or 100hp, with electrical starter,
dual electronic ignition, integrated reduction gear box,
ground adjustable 3-blade or 2-blade propeller.
Standard Glass-fibre fairings (as above), (partly as sandwich
construction).
Equipment: Highly effective hydraulic disc brakes with parking brake.
UV-stable GT-foil coverings for wings and empennage
available (std colour: white).
High-lift flaps with separate aileron.
Stick mounted electric elevator trim.
Gas-pressure spring assembly for cabin doors.
Flight instruments: Altimeter, airspeed indicator, compass,
bank indicator.
Engine instruments: RPM indicator, oil pressure indicator,
oil temperature gauge,
water temperature gauge, fuel gauge.
Cabin heating, adjustable fresh-air inlets for both seats.
65 litre Fuel Tank.
High power/ low weight sealed lead acid battery, 12 Volt
power socket.
Seat Cushions, map pockets, door locks, floor mats.
Nose and main wheel fairings. Red or Blue stripe.
Radio Antenna.

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2.1.1 Optional Items
Propellors Refer to POH for types cleared for use
Airframe Carbon Fibre Shells (saves 4kg)
Wingtips Lightweight Version (White only)
Wingtips Coloured (Red or Blue) VLA only
Scratch Resistant Front Window
Cabin Ceiling Window
Cabin Ceiling Window - Bronzed
Folding Wing Kit (supplied separately)
Main Wheel Strut Fairings
Suspension Points (Hanging Storage)
Instruments Vertical Speed Indicator - approx 80mm
Vertical Speed Indicator - approx 55mm
Operating Hours Meter
Artificial Horizon (Vacuum or electric)
Vertical Card Compass 57mm )
Fuel Computer (Fuel CAT)
Master Caution Warning System (Comco Design)
VHF Comms Filser ATR500 radio (inc intercom)
Filser ATR600 radio (inc intercom)
Filser TRT 600 Mode S/C Transponder
Microair radio 760
Microair Transponder T2000 mode C
Exterior Lighting Nose Wheel Landing Light (single bulb)
Strobe Light - single light mounted on Fin
Exterior fitment Lotus Floats System
Glider towing Kit

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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.
Annoying covering of the cowl flap in cold weather is a thing of the past. As a
result, optimally regulated engine temperatures as well as shortened warm-up
period of the engine minimizes fuel consumption and prolongs the life span of
the engine.
Installed temperature warning sensor (red warning light) will notify that the flap
is not opened.
II. Mechanical Installation:
- Dismantle lower cowling.
- Put on the housing of the cowl flap and fix it with 2 bolts M4 at the upper and
lower inlet lips.
Figure 7: Bolts M4
- In flight direction left, about 10 cm from below cut a slot for the Bowden cable
in the GRP sealed radiator surface of the cowling (e.g. with a small drill or
round file)
.
Figure 8: slot

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- 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.
Figure 10: Exhaust pipe
- Fasten the actuating lever to the hinge bar with 2 x M5 countersunk head
screws and locking nuts (left at pilot’s side).
Figure 11: actuating lever
Lead the Bowden cable under the instruments panel to the actuating lever,
adjust the length with a clamping screw and clamp it
.
Figure 12: Bowden cable

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- 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.
- Mount the temperature switch, move up the sensor cable with abrasion
protection between both left cylinders and push it through the central firewall
aperture.
Figure 13: temperature switch
- In the appropriate place at the pilot’s side drill a hole for the warning light and
mount it.
Figure 14: warning light / actuating lever
- Connect the sensor cable with a cable shoe to the warning light.
- Connect the second port of the warning light with instruments " + ".
- Make functionality test with turned on main switch by removing the sensor
cable from the temperature switch and hold it against mass.
Important The light must be on.

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IV. Operating Instructions:
- Before starting the cold engine the cowl flap can now be closed with the
actuating lever.
- When reaching the cylinder head temperature of about 90° C the cowl flap
can be again fully or partially opened depending on the outside temperature.
- In case the flap was forgotten to be opened, the red warning light will light up
when the cylinder head temperature reaches 130° C. The cowl flap should be
then forthwith fully opened as well as the engine output should be reduced if
possible so that to allow for an immediate cooling down of the engine.
- For dismantling the lower cowling (100 h control, oil change) the Bowden
cable can be disconnected directly on the cowl flap. For that, after removal of
the circlip it is necessary to pull the cotter bolt and by unscrewing the lentil-
flange head screw (long Allen key) to remove the Bowden cable holder. The
cowling can be now dismanteled without problems.
- 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
2.1.4 Consumable items
Tyres, oil, coolant, battery, spark plugs, oil filter, fuel filter, fuses,
Part Description
Tyres 4.00 x 6 4 ply rating
Inner tubes 4.00 x 6 angled valves
Coolant Glycol based @ 50% concentration
Engine oil Shell Advance VSX 4
Battery 12 Volt 12 AH YTX14-BS (Hawker)
Spark Plugs NGK DCPR7E (80hp) NGK DCPR8E (100hp)
Oil Filter Rotax 912 825 701
Fuel Filter Nylon mesh filter with 8mm connections
Fuses Automotive 12 volt blade fuses (30, 15 & 5 amp rating)