COMCO IKARUS
Maintenance Manual C42 Series
MaintenanceManual C42-
Series_Issue_VII_18.02.2014.doc
Revison No.:1 91 from 107
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. Punch out the mandrel using the appropriate puncher.
2. Drill out the rivet head without damaging the bore-hole.
3. Punch out the remaining shaft using a suitable puncher
4. Set the new rivet (pay attention to rivet type, grip length and diameter!)
5. Pull the rivet using the appropriate tool (electrical, pneumatic, hydraulic or
manual riveting tool)
5.4 Glass repairs
The windscreen/windows made of Makrolon® are extremely difficult to repair. As
spare parts are cheaper, it makes more sense to replace any damage glass. If the
damage is large-scale, particularly if visibility is adversely affected, the glass pane
has to be replaced. Spare parts are available from any IFC / ISC or from COMCO
IKARUS GmbH directly.
Small-scale damage can be repaired without great effort.
It is indeed often possible to remove small scratches simply by polishing the surface.
Deeper scratches can be sanded down (1000 - 1400 grain).
Small cracks and fissures can be repaired by stop-drilling:
A stop hole is drilled at both ends of the crack/fissure using a 2mm borer thus
preventing the crack/fissure from growing further.
The crack/fissure can then be repaired by grinding a V-shaped groove into the crack
and filling it with a special polycarbonate adhesive. Cracks/fissures repaired with
polycarbonate adhesive are liable to distortion. Once the adhesive has hardened, the
area should be wet-sanded (1000 - 1400 grain). Finally, the spot should be polished
with polishing wadding.
It is, however, often simpler and less time-consuming to replace the glazing.
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