Maintenance Manual Ikarus C42 Series

IKARUS GmbH instructions (only if a variable pitch propeller is installed) in accordance with COMCO IKARUS GmbH instructions Nose wheel landing gear 48 Check nose gear fairing for secure fitting and damage; repair or replace as required x x Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 60 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours 49 Check wheel pant and wheel pant bracket for secure fitting and damage; repair or replace as required x x 50 Check attachment of nose wheel spar to fuselage tube; check screws in and under the engine mount for secure fitting x 51 Check nose wheel fork for deformation and other damage x 52 Check suspension rubber boots for damage, porosity, etc. (year of construction before 2003) x x 53 Check functionality and condition of damping spring (year of construction before 2003) x x 54 Check functionality and condition of rubber spring elements above and below nose wheel spar (year of construction 2003 and younger); check particularly for cracks, porosity, deformation; replace as required x 55 Check nose wheel fork for play and freedom of movement in direction of rotation and compression x x 56 Check steering rods, joints, push-rods and links of the floor pedals of the nose wheel steering for secure fitting, damage and abrasion x x 57 Clean, grease and secure rod ends of the pedal controls at the pedals and steering rods x 58 Check axial attachment screw of the nose wheel fork for secure fitting x 59 Grease both journal bearings in the nose wheel spar with a grease press via upper and lower grease nipples x 4.3.3.1 Tyres 60 Check tyre for damage, uneven wear, age and tread; replace as required x x 61 Check tyre pressure; adjust appropriately x x Wheel rim 62 Check for damage, deformation, cracks; replace if necessary x x 63 Check condition of valve x x 64 Check wheel bearings for play and freedom of movement x x Main landing gear 65 Check main landing gear fairing for secure fitting and damage; repair or replace as required x x 66 Check wheel pants and wheel pant brackets for secure fitting and damage; repair or replace as required x x 67 Check cross beam for damage and deformation (visual inspection of beam); check screw connections between fuselage fittings and cross beam for secure fitting (visual inspection under the seats) x 68 Check rivet connections between cross beam and joists x Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 61 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours 69 Check axle tubes (swing axles) for damage and secure fitting; check connections and bearings, in particular plastic spacers between the joists on the cross beam x x 70 Check condition of trailing arm for damage, secure fitting and freedom of movement of the rod ends x x 71 Check condition of spar struts for damage and secure fitting (inspection through baggage bin) x x 72 Check shock absorber rubber boots for damage and porosity; replace as required x x 73 Check functionality, condition and attachment of shock absorbers; pressure check x 4.3.3.2 Tyres 74 Check tyres for damage, uneven wear, age and tread; replace as required x x 75 Check tyre pressure, adjust appropriately x x Wheel rims 76 Check for damage, deformation and cracks; replace if necessary x x 77 Check condition of valves x x 78 Check wheel bearings for play and freedom of movement x x Brakes 79 Check braking function x x 80 Check attachments of lines to main landing gear x x 81 Check brake system in its entirety for damage and leaks; repair leaks, fill up with brake fluid and ventilate system as required x 4.3.4.1 82 Check proper attachment of lines to the brake lever and the brakes x x 83 Visual inspection of brake pads, check for uneven, asymmetrical wear or reaching wear limit; replace pads if necessary x x 4.3.4.2 84 Check brake discs for wear and true running; replace as required x Wing 85 Check wing tips/winglets for damage; repair or replace as required x x 86 Visual inspection of covering for any kind of damage and integrity of seams; repair if necessary x x 87 Check wing attachments for play. Move the wing tips up and down and back and forward; if necessary, tighten the M8 attachment screws on the U fittings of the wing attachment (25 Nm) x x 88 Check wing struts and auxiliary struts for damage and secure attachment x x 89 Check wing battens; repair or replace any damage battens x x 4.3.5.1 Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 62 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours 90 Check the diagonal cables for correct tension Note: This inspection can be done through the open zips of the wing covering and from the cockpit through the wing-fuselage junction x x Ailerons 91 Visual inspection of the condition of the ailerons x x 92 Check ailerons for freedom of movement x x 93 Check condition, secure fitting, play and security of the aileron hinges (fork joints), in particular wear of the eye-bolts and bolts x x 94 Clean, grease and secure fork joints x 95 Check aileron control horn for damage, secure fitting and security x x 96 Check attachment of aileron rod: - control stick - torsion tube - axial screws on the front and rear bearings of the stick- torsion tube for secure fitting of the screws and their safety pins - pulleys: condition, attachment and bearings - aileron quadrant at canopy roof frame: attachment and bearings - pulleys in the wings: attachment and bearings x 97 Check condition of aileron rod ends: - torsion tube front and rear - aileron quadrant - aileron control rod, long – direction changer - aileron control rod, short - control horn – direction changer x x 98 Clean, grease and secure rod ends and check for play x 99 Check security of aileron push-rods short/long x x 4.3.5.2 100 Check quick-release fittings of the aileron push-rods at the aileron quadrant for freedom of movement and secure closure x x 101 Check aileron cables, thimbles and swaged grommets for damage and secure attachment x 102 Check cable tension of the aileron quadrant; if necessary, adjust using eccentric wheel x x 4.3.6.1 103 Check aileron quadrant and lever arms in the wing for freedom of movement and security; if necessary, wash out the journal bearings and grease x Wing flaps 104 Visual inspection of the condition of wing flaps x x 105 Check condition, secure fitting, play and security of wing flap hinges (fork joints), in particular wear of the eye-bolts and bolts x x 106 Clean, grease and secure fork joints x Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 63 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours 107 Check functionality, freedom of movement and play in the controls x x 108 Check fitting of sliding sleeves on the flap spar; sliding sleeves and spars must fit exactly into each other x x 4.3.6.2 109 Loosen the sliding sleeves and check for wear; clean and grease as required x 110 Check the spring-loaded locks at the sliding sleeves for proper form fit (they must positively lock at the front and rear end of the tubes) x x 111 Check spring-loaded locks freedom of movement x 112 Check the wing flap steering rod for damage and secure fitting x x 113 Check condition of swivel heads of connections: steering lever - wing flap push-rods - actuator lever x x 114 Clean, grease and secure swivel heads and check for play x 115 Check secure fitting and functionality of wing flap link and actuator lever Note: The detents in the flap track tend to enlarge with time; if the flap lever shows significant play in one of the detents the flap track must be replaced x x 116 Grease the flap tracks x Fuselage Frame 117 Check metal frame (fuselage tube, A/B/C columns, canopy roof frame, struts, fittings, etc.): - screw connections - rivet connections - welded connections - joints - deformations x x ATTENTION: Reference to SB-42-022-2019: In case of damage history and/or more than 2000 operating hours (see SB-42-022-2019), the inner surface of the A-strut at the junction to the upper main tube mount shall be inspected with an endoscope every 300 hours. Skin 118 Check condition of all glass-fibre and carbon-fibre shells, fairings and cowlings for damage, cracks, deformation, etc.; repair or replace any damaged elements x x 119 Check functionality of fuselage shell attachments and that none are missing x x 120 Check proper attachment of mounted parts such as antennas, etc. x x 121 Check rubber sealing around the opening of the ballistic recovery system x x 122 Check proper functioning of the Camloc locks in the baggage bin cover x x Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 64 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours Towing mechanism (if installed) 123 Maintenance in accordance with the appropriate documents (tow hook E85) in accordance with COMCO IKARUS GmbH instructions operating manual 124 Check Bowden cable for freedom of movement and damage near the release lever and near tow hook; this check should be carried out before every flight x x 125 Check release force at the release lever when the tow hook is unloaded (< 13 daN); this check should also be carried out every 200 tows x 126 Clean and grease Bowden cable at the adjustment screws near the release lever and the tow hook; this check should also be carried out every 200 tows x Doors and windscreen 127 Check the front door attachment bolts for cracks near the attachment screws x x 128 Check seals for damage and porosity x x 129 Check glass for cracks, scratches; repair or replace damage elements as required x x 130 Check condition and functionality of cabin locks x x 131 Check condition and functionality of ventilation window x x Empennage Horizontal tail 132 Check condition of horizontal tail struts and for secure fitting x x 133 Visual inspection of the condition of the horizontal tail fin and of the elevator x x 134 Check horizontal tail fin for secure fitting x x 135 Visual inspection of safety screws in the horizontal tail fin attachment x x 136 Check condition, secure fitting, play and security of elevator hinges (fork joints), in particular wear of the eye-bolts and bolts x x 137 Clean, grease and secure fork joints x 138 Check elevator control horn for damage, in particular for cracks in the welded connection, and for secure fitting x x 139 Check freedom of movement of the elevator x x 140 Check condition and freedom of movement of the elevator push-rod rod ends; with the elevator in full deflection, check counter nuts for secure fitting x x 141 Check counter nuts for proper torque and that they are properly installed x x Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 65 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours 142 Clean, grease and secure rod ends and check for play; tighten and secure the counter nuts with Loctite; secure rod end with counter nut x 143 Check condition, security and attachment of elevator direction changer (on top of fuselage tube); in particular, check screws in the bearing block, fittings and rivets; observe service bulletin x x 4.3.6.3 144 Check elevator direction changer for security, wear and freedom of movement; wash out and grease journal bearings x 145 Check attachment of push-rod to control stick x x Trim tab 146 Check trim tab functionality and lever arm (cf. setting data) x x 147 Visual inspection of condition and attachment of tab, control horn and control rods Note: The bearing "rod-control horn" used in the design prior to 2004 can wear out. Retro-fit new construction as required x x Electrical trim tab 148 Check functionality and the connections for secure fitting (insofar as they are accessible, cf. circuit diagram) x x Mechanical trim tab 149 Check function, condition and attachment of the Bowden cable; if stiff, oil using an injection syringe or replace x x 150 Check counter nuts of the Bowden cable adjusting screws x x Vertical tail 151 Visual inspection of the condition of vertical tail fin and rudder x x 152 Check vertical tail fin for secure fitting x x 153 Check guide bushing of forward and aft vertical tail attachment in fuselage tube for play; replace, if necessary x 154 Check condition of rudder hinges (fork joints) x x 155 Clean, grease and secure fork joints and check for play x 156 Check freedom of movement of rudders x x 157 Check cables and Bowden cables for secure attachment, correct routing, damage, wear and tension; adjust and grease as required x x 158 Check counter nuts of the Bowden cable adjusting screws x x Maintenance Manual Ikarus C42 Series Issue VIII Rev. 1 66 of 103 No. Description Inspection Ref. Chapter Signature every 50 hours every 100 hours Interior/Cockpit Battery 159 Visual inspection of wires, connections and wire routing for integrity and security insofar as accessible x x 160 Visual inspection of attachment x x 161 Check that battery is charged, recharge if necessary x x Instrument panel 162 Check condition and attachment of instrument panel (attachment clips) x x 163 Check attachment of each individual instrument x x 164 Check functionality of control elements: - choke - cabin heating - carburettor heating x x Pitot-static pressure system 165 Visual inspection of condition and attachment of pitot tube on the left wing x x 166 Check system for leaks x x 4.3.8 Flight controls 167 Check control stick attachment x x 168 Check control stick for freedom of movement x x 169 Check throttle for freedom of movement and sufficient friction x x 4.3.6.4 170 Check Bowden cables for freedom of movement; grease if necessary x x Pedal assembly 171 Check condition and attachment of pedals (in particular, check for deformation and the condition of the welded connections) x x 172 Check attachment and security of push-rods and control cables 173 Check pedals for freedom of movement Seats 174 Check seats for damage x x 175 Check condition and attachment of safety belts, check functionality of belt locks x x Other 176 Check attachment of the side panelling of the centre console (thread- forming self-tapping screws, M3 screws and attachment clips) x x 177 Check that placards are legible and none are missing x x Engine test run in accordance with Rotax operating handbook Test flight