Maintenance Manual IKARUS C42 Series

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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 2 from 107 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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 3 from 107 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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 4 from 107 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. COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 5 from 107 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. COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 6 from 107 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. COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 7 from 107 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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 8 from 107 Figure 3: Ikarus C42C COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 9 from 107 Figure 4: Three-view Ikarus C42 / C42 UK Figure 5: Three-view C42B / C42 B UK/ C42E COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 10 from 107 Figure 6: Three-view C42C COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 11 from 107 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. COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 12 from 107 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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 13 from 107 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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 14 from 107 - 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 COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 15 from 107 - 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. COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 16 from 107 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) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 17 from 107 2.1.5 Recommended Stocking List QTY Description 1 Set brake discs 2 Complete set brake pads 3 Tyres 3 Inner tubes 1 Suspension air pump 1 Metric socket set 1 Metric allen key set 1 Litre LHM fluid 1 Nose wheel axle 1 Front forks 1 Square tube 2 Fuel filters 8 Coolant radiator mounting rubbers 10 Long exhaust springs 5 Short exhaust springs 1 3 metres 8mm Trelleborg fuel hose 1 3 metres 6mm Trelleborg fuel hose 1 3 metres 8mm clear urethane hose 1 3 metres 6mm clear urethane hose 20 Size 11.5 fuel line clips 20 Size 12 fuel line clips 20 Size 14 fuel line clips 20 8mm cummipuffers 20 4mm hex head screws 20 Complete engine cowl camlocs 10 Complete long wing nut camlocs 10 Complete short wing nut camlocs 10 Complete lower engine cowl fixing COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 18 from 107 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. Note :-For detailed weight and balance limitations you must refer to the P.O.H. appropriate to the aircraft in question. 2.2.1 Weight and Balance Calculations The centre of gravity is measured in mm behind the zero datum. Zero datum is the leading edge root. The aircraft’s empty weight and cg are derived first: Place the aircraft in a level position on three scales, such that the stabilizer is horizontal, as shown below. Push down on the rear fuselage, just in front of the tail, and chock the nose wheel to level the aircraft. Record the reading of each scale. Calculate the position of the empty cg, from the formula: mm G G b G a ...... .......... X 2 1 1 = + × − = (a and b are values to be measured for the specific aircraft). a x G1 G2 = GL + GR b COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 19 from 107 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. Complete the remaining weights for seat loads, fuel and baggage and multiply these by the lever arm lengths (given below). Add up the weights and moments, then divide the total weight by the total moment to give laden cg location aft of datum. L oa d in g p lan Pos i tio n w eig ht x le ve r arm = m om e nt lb (k g) in . (m m ) lb in (k gm m ) Em p ty w eig ht 1. S ea ts 15 .7 ( 400 ) 2. F u el 37 .4 ( 950 ) 3. B ag gag e 5 1.2 (13 00) T otal W e igh t lb ( kg ) T otal M o m en t lb in (k g m m ) T o ta l Mo m en t lb i n (k gm m ) c entre o f gr av ity C G = -- ----- ------ ------ ----- ------ ----- ------ - = c min (m m ) T o ta l W ei ght lb (k g ) Centre of gravity range is dependant on aircraft model. Refer to POH. 2.2.2 Conditions of Weighing The dry empty weight of the aircraft is defined under the following conditions: All normal installed equipment fitted. Oil and coolant levels normal. No usable fuel. Note: Remaining within the Maximum Take-off Weight (MTOW) as specified in the P.O.H. is the pilot’s responsibility. COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 20 from 107 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. Figure 15: Fuselage design Figure 16: Standard wing design without winglet *only valid for standard wing without winglet C column B column push-rod elevator control torsion tube aileron control cross beam canopy roof frame A column engine mount fuselage tube diagonal strut compression strut* wing flap diagonal bracing cable aileron rear wing tube root rib wing strut bellcrank, aileron forward wing tube wing tip * aileron control rod, long aileron control rod, short COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 21 from 107 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®). The polycarbonate Makrolon® is used for the glazing. Makrolon® is a high-tech polycarbonate (not plexiglass) which is characterised by its resistance to weather, heat and cold, its impact strength and its light weight. However, the material is particularly susceptible to solvents and petrol. Beginning with the production date 04/2008, a special, impact resistant plexiglass has been available as an option. This special plexiglass is characterised by a better buffability and its resistance to petrol and oil. elevator trim elevator veritical tail fin horizontal tail fin empennage strut rudder COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 22 from 107 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. However, since 2003 spring elements made of polyurethane have replaced the pressure spring. The nose wheel fork is stored in the nose wheel spar which passes through the fuselage tube and the engine mount and is attached to the engine mount by means of a mounting bracket. Figure 18: Nose wheel landing gear 2.4.1 Main landing gear: The main landing gear comprises the cross beam, joists, axle tubes, shock absorbers, trailing arms and spar struts as well as wheel axles and main wheels. The individual elements of the landing gear are connected to each other by screws. Figure 19: Main landing gear steering bar nose wheel mount (nose wheel spar) nose wheel fork rubber boot with subjacent spring (before 2003) axle bolt fuselage tube engine mount spar strut cross beam trailing arm axle tube shock absorber wheel axle fuselage tube joists polyurethane spring elements (since 2003) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 23 from 107 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. The C42B / C42B UK / C42E has a new cowling which is 13 cm longer, the engine has been set 6 cm forward and the windscreen is shallower. In addition, the air induction system and the coolant and oil cooling systems have been altered. These alterations in particular have led to considerable improvements in performance and to a reduction in the warm-up phase. 2.5.2 Engine: The aircraft is powered by an 80 hp or 100 hp rated, mixed liquid-cooled/air-cooled, opposed 4 cylinder, 4 stroke Rotax 912UL or 912ULS engine. Both engines have an electrical starter, electronic dual ignition and an integrated reduction gear. The C42B / C42B UK / C42E also has carburettor heating. A detailed description of the engines and the necessary maintenance measures are given in the Rotax documents. Figure 20: Rotax 912UL engine (C42 / C42 UK) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 24 from 107 Figure 21: Rotax 912UL engine (C42B / C42B UK / C42E) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 25 from 107 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. This results in a 2-3% improvement in performance. In the event of carburettor icing, an adjustable flap in the induction tube reduces the amount of outside air being fed into the system. Instead, additional warm air flows in from the exhaust shroud. Figure 22: Air induction system C42 / C42 UK Figure 23: Air induction system C42B / C42B UK /C42E air filter C42 / C42 UK carburettor exhaust shroud carburettor induction air flow with integrated air filters, C42B / C42B UK / C42E flap, outside air flow (does not close completely!) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 26 from 107 Issue V1 / December 2009 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. In the case of the C42B / C42B UK/ C42E, only the coolant is cooled by a cooler. The coolant and oil systems are connected to one heat exchanger, thus the temperatures of both fluids adapt to each other. The temperatures of the coolant, oil and cylinder head of the C42B / C42B UK / C42E are, therefore, almost identical. Due to heat exchange the oil also warms up faster during the run-up phase. It is, however, still necessary to mask the water cooler if optimum engine temperature (>90°C) is to be achieved during cold weather operation (max. one third of the surface may be covered with tape or self-adhesive neoprene). More detailed information on engine cooling and the relevant maintenance measures are to be found in the appropriate Rotax documents. Figure 24: Cooler C42 / C42 UK Figure 25: Cooler C42B / C42B UK /C42E oil cooler coolant cooler heat exchanger coolant cooler COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 27 from 107 2.5.5 Propeller: The aircraft may be equipped with a 2 bladed or 3 bladed, ground-adjustable, carbon-fibre, glass-fibre or wooden propeller and a glass-fibre spinner. If a Rotax 912ULS engine (100 hp) is installed in the C42, it may also be equipped with a hydraulically or electrically adjustable propeller. Information on certified propellers is to be found in the current technical data sheet or in the pilot’s operating handbook. 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. Figure 26: Exhaust system COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 28 from 107 2.6 Fuel system Figure 27: Schematic diagram of the fuel system C42 / C42B Figure 28: Schematic diagram of the fuel system C42 UK / C42B UK / C42E Drain valve Fuel filter Andair check valve Electric fuel pump Fuel tap Mechanical fuel pump Left carb Right carb Firewal Sump Fuel tank vent Fuel tank Vapour return line Filler nozzle right and left carburettor mechanical fuel pump fuel level sensor tank filler tank tank ventilation fuel valve fuel filter fuel tank sump drainage valve firewall electrical fuel pump electrical fuel pump by-pass T fitting with screwed-in restriction valve T fitting flow sensor for CAT fuel computer (optional equipment) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 29 from 107 Figure 29: Fuel system components C42 / C42 UK tank ventilation fuel level sensor tank filler fuel filter electrical fuel pump electrical fuel pump by-pass T fitting with restriction valve flow sensor for CAT fuel computer (optional equipment) fuel valve drainage valve under right pilot seat mechanical fuel pump COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 30 from 107 Fuel tank components Electric fuel pump & Andair check valve Figure 30: Fuel system components C42 UK / C42B UK / C42E Andair check valve Electric fuel pump Electric fuel pump by-pass pipe Vent tube Filler nozzle Fuel gauge sender Vapour return tube COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 31 from 107 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. For balance reasons, the battery is placed further back in aircraft without a ballistic recovery system. Circuit diagrams are to be found in the appendix of this manual. Figure 31: On-board battery C42 / C42B / C42E Figure 32: On-board battery C42 UK / C42B UK ( optional) COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 32 from 107 Electrical parts Please refer to the schematics below. 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 ) Figure 33: Electrical parts (old regulator to 2008 ) Earthing points Regulator / rectifier Starter motor solenoid COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 33 from 107 Figure 34: Electrical parts (new regulator since 2008 ) Earthing points Regulator / rectifier Starter motor solenoid COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 34 from 107 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. Elevator deflection is limited by two polyamide spacers. Figure 35: Elevator control 2.8.2 Trim: The aircraft is available with a mechanical or (as an option) an electrical trim system. In the case of the mechanical trim system, the trim tab is adjusted by a lever in the canopy roof frame and a Bowden cable. The trim tab of the electrical trim system is adjusted via buttons on the control stick which activate a trim servo and rod. The circuit diagram for the electrical trim system is to be found in Chapter Fehler! Verweisquelle konnte nicht gefunden werden.. Figure 36: Mechanical trim elevator reversal bellcrank elevator push-rod elevator control horn trim lever trim tab control horn Bowden cable COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 35 from 107 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. The cables are re-directed by two pulleys mounted on the cross-rod of the canopy roof frame and routed to the aileron quadrant. From the quadrant, the ailerons are actuated via two aileron rods and a bellcrank per wing. Figure 38: Aileron activation aileron control horn aileron quadrant aileron torsion tube bellcrank trim tab control horn trim servo underneath the covering COMCO IKARUS Maintenance Manual C42 Series MaintenanceManual C42-Series_Issue_VII_18.02.2014 Revison No.:1 36 from 107 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. The Bowden cables are crossed over under the seats. Figure 39: Rudder control system C42 / C42B 2.8.5 Nose gear steering: The nose wheel landing gear is steered via the floor pedals. Push-rods actuate the steering bar connected to the nose wheel fork. Figure 40: Nose wheel steering system C42 / C42B rudder control horn Bowden cable drive attachment rudder Bowden cables push-rod drive attachment steering bar nose wheel fork in nose wheel mount