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Chapter 15

PLACARDS AND MARKINGS /

15-1

CHANGE C1

ICON A5 / MAINTENANCE MANUAL

CHA

R 15

PLACARDS AND MARKINGS

Placards and Markings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3

Placards and Markings General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Fuel Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Max Amperage for USB and 12V Accessory Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Maneuvering Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Baggage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Secure Loose Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Window Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5

Window Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Wind Deflector Alignment and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Window Out Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Keep Hands Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Open Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Passenger Warnings and Kinds of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Registration Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Fuselage Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-7

Do Not Jump Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8

ELT Remote Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8

Parachute Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9

Parachute Activation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9

Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9

Canopy Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9

Danger Explosive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9

Ballistic Parachute Passenger Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10

Parachute Egress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10

Wing Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

Wing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11

Keep Static Port Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

Aircraft Data Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-12

Summary of Contents for A5

Page 1: ...00833 Issue C3 Airplane Registration Number __________________________________________________ Airplane Serial Number _________________________________________________________ Date 28 February 2019 IC...

Page 2: ...ft Inc 2141 ICON Way Vacaville CA 95688 https www iconaircraft com All rights reserved No part of this manual may be reproduced or cop ied in any form or by any means without written permission of ICO...

Page 3: ...ystem 6 Environmental Control Utility Systems 7 Equipment and Furnishings 8 Flight Controls 9 Fuel System 10 Fuselage and Vertical Tail 11 Horizontal Tail 12 Instruments and Avionics 13 Landing Gear 1...

Page 4: ...IV TABLE OF CONTENTS ICON A5 MAINTENANCE MANUAL ISSUE C3...

Page 5: ...SIONS 1 1 CHANGE C3 ICON A5 MAINTENANCE MANUAL CHAPTER 1 REVISIONS Record of Maintenance Manual Revisions 1 2 Issue C3 1 2 Issue C2 1 5 Issue C1 1 6 Issue C 1 9 List of Effective Chapters 1 12 Manual...

Page 6: ...ng Gear Condition and 100 Hour Inspection Issue Date Chapter s Added By A 8 June 2015 All ICON Aircraft A1 25 January 2016 1 2 3 4 5 7 9 10 13 ICON Aircraft A2 16 March 2016 1 2 3 4 5 6 8 9 10 12 13 I...

Page 7: ...d Landing and Taxi Lights section Updated Battery Description Updated Replace Coarse Fuel Filter Move Bilge Pump from Chapter 7 Updated Charge Battery Chapter 7 Move Bilge Pump section to Chapter 7 Ch...

Page 8: ...ded Remove Fine Fuel Filter Added Install Fine Fuel Filter Chapter 12 Added Horizontal Tail Tip Lock Switches section Chapter 13 Added DAC Software Version section Updated the Instruments and Avionics...

Page 9: ...ler section Updated A5 Specific Oil Change Procedures Updated Install Engine Cowlings Updated Remove Engine Cowlings Updated Inspect Engine Mount Added ECU Troubleshooting Chapter 17 Updated Wing Lock...

Page 10: ...100 Hour Inspection Avionics and Electronics Chapter 6 Updated chapter description Added Grease Coil Pack Connections task Added Inspect Repair and Secure Wiring Harness with Signs of Chafing Added Wi...

Page 11: ...stall Roll Trim Tab task Added Determine Roll Trim Tab Length task Added Pitch Controls description Added Pitch Controls diagram Added Pitch Trim Actuator description Added Pitch Trim Actuator diagram...

Page 12: ...acement Procedure Updated step five of MLG Wheel and Axle Installation Updated step 2 of MLG Actuator Removal Updated Replace Nose Landing Gear Actuator task Updated name of Aft Nose Landing Gear to A...

Page 13: ...9 Added IPS Description Added Parachute Package Removal Added Parachute Package Installation Added Harness Installation Added Extraction Rocket Removal Added Extraction Rocket Installation Added Armin...

Page 14: ...ng Added Rudder Rigging procedure Added Elevator Rigging procedure Changed Complete Aircraft Parachute to ICON Parachute System IPS Chapter 12 Added Measure Horizontal Tail Tip Anti Rotation Pin Wear...

Page 15: ...REVISIONS RECORD OF MAINTENANCE MANUAL REVISIONS 1 11 CHANGE C3 ICON A5 MAINTENANCE MANUAL CHAPTER 1 Chapter 19 Changed Complete Aircraft Parachute to ICON Parachute System IPS...

Page 16: ...C2 28 February 2019 5 DOORS AND WINDOWS C0 20 April 2018 6 ELECTRICAL SYSTEM C2 28 February 2019 7 ENVIRONMENTAL CONTROL UTILITY SYSTEMS C1 28 February 2019 8 EQUIPMENT AND FURNISHINGS C1 28 February...

Page 17: ...INTENANCE MANUAL CHAPTER 1 Applicable to Maintenance Manual Revision Issue C3 RELATED INFORMATION Manual Revisions on page 1 14 20 STRUCTURAL REPAIR C0 20 April 2018 21 PAINTING AND COATINGS C0 20 Apr...

Page 18: ...pdated when handbook revisions are issued by ICON Updates and changes to chapters of the manual are called Changes and are designated using the issue prefix followed by a number for example Change A0...

Page 19: ...Minimum Levels of Certification 2 12 Level of Certification Hierarchy 2 12 Major Repairs and Alterations 2 13 Safety Directives and Continued Operational Safety 2 14 Instructions for Reporting Safety...

Page 20: ...Locking Nuts 2 30 Castle Nuts 2 31 Clevis Pins 2 31 Cotter Pins 2 31 Threaded Taper Pins 2 31 Safety Wire 2 31 Turnbuckles 2 31 Threadlocker 2 31 Fabricated Cable Assemblies 2 32 Torque Procedure and...

Page 21: ...major Major repairs alterations or maintenance tasks require coordination and approval from ICON Aircraft before any work commences The minimum levels of certification to perform any minor task are al...

Page 22: ...dicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation or instruction which if not avoided or follow...

Page 23: ...hazards participating in training following all applicable safety policies and procedures and promptly reporting hazards and accidents to their supervisor Maintenance personnel should pay particular...

Page 24: ...light sport aircraft with a maintenance rating as defined by 14 CFR Part 65 or equivalent rating issued by another civil aviation authority who is authorized to perform line maintenance on aircraft ce...

Page 25: ...ndition inspection except the interval of inspection is 100 hours of operation instead of once in the preceding 12 calendar months This inspection is utilized when the LSA is flown 100 hours before th...

Page 26: ...ER 2 MLG Main Landing Gear MM Maintenance Manual MRA Major Repair and or Alteration NLG Nose Landing Gear PIM Parachute Installation Manual RF Radio Frequency RH Right Hand TED Trailing Edge Down TEL...

Page 27: ...ICON Parachute System Structural Repair and Paintings and Coatings The Feedback Forms chapter provides additional reference information Each task provided in this MM is structured using the following...

Page 28: ...UAL ICON A5 MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 RELATED INFORMATION Line Maintenance Repairs and Alterations on page 2 11 Heavy Maintenance Repairs and Alterations on page 2 11 Overhaul on page 2 1...

Page 29: ...ork must hold at least a Sport Pilot certificate RELATED INFORMATION Organization and Structure of This Manual on page 2 9 2 6 3 Heavy Maintenance Repairs and Alterations There are no heavy maintenanc...

Page 30: ...Maintenance LSA RM Items that can be expected to be completed on a SLSA by a responsible individual who holds an FAA repairman certificate light sport aircraft with a mainte nance rating A P Items tha...

Page 31: ...or alteration MRA and requires prior approval from ICON Aircraft If ICON Aircraft agrees to provide an MRA then ICON will evaluate the change against the require ments of the applicable ASTM standards...

Page 32: ...formation will be included either directly or by reference within the notice A list of the tools needed to accomplish the task A list of parts needed to perform the task The type of maintenance The le...

Page 33: ...GENERAL SAFETY DIRECTIVES AND CONTINUED OPERATIONAL SAFETY 2 15 CHANGE C3 ICON A5 MAINTENANCE MANUAL CHAPTER 2 RELATED INFORMATION Safety Directives and Continued Operational Safety on page 2 14...

Page 34: ...e periodic inspections maintenance or over haul The maintenance schedules listed in the Related Information below summarize the required work by calendar time and operational hours RELATED INFORMATION...

Page 35: ...FAA Exemption 10829 for the ICON A5 the logbook entry for any maintenance performed on the aircraft must reference the exemption The exemption states the following Any person who performs maintenance...

Page 36: ...C3 CHAPTER 2 2 10 Sources to Purchase Parts Parts can be acquired from ICON Aircraft ICON Aircraft Inc 2141 ICON Way Vacaville CA 95688 001 707 564 4000 RELATED INFORMATION https www iconaircraft com...

Page 37: ...ts on page 2 18 Item Part Number Source Main Gear Tires DTAB3D3 Desser Tires Nose Gear Tire ICA013789 Desser Brake Pads ZEA01 Beringer Coarse Fuel Filter FX 375 M Andair Fine Fuel Filter 874060 Rotax...

Page 38: ...s may be purchased through ICON Aircraft FIGURE 2 1 TIE DOWN ADAPTER QRP9C0405 Tool ICON Part Number Tie Down Adapter QRP9C0405 Fuel Sumping Tool ICA009753 Wing Jack Point Adapter ICA009750 Nose Landi...

Page 39: ...MANUAL CHAPTER 2 FIGURE 2 2 FUEL SUMPING TOOL ICA009753 FIGURE 2 3 WING JACK POINT ADAPTER ICA009750 The following list of special tools may be needed to complete the inspection and maintenance of the...

Page 40: ...Protractor Densimeter Glycol Tester Caliper Mircometer Calibrated Torque Wrench Digital Level with 0 1 resolution 3M Adhesion Promoter 111 14 125 125 VDC Charge with current capability of at least 4...

Page 41: ...ubble level located under the passenger floorboard panel For details on determining the empty weight and balance by either of these methods see Related Infor mation below For a current status of empty...

Page 42: ...intenance procedures allowed that affect weight and balance Any modifications to the aircraft equipment require the prior approval of ICON Aircraft Should such work be necessary ICON will supply any n...

Page 43: ...flated to 45 psi Each landing gear assembly is equipped with one wheel and tire The main landing gear tires are size 5 00 5 6 ply aircraft tires with a maximum load rating of 1 285 lbf The nose gear t...

Page 44: ...ly opposed spark ignition engine single central camshaft overhead valves Liquid cooled cylinder heads Ram air cooled cylinders Dry sump forced lubrication Fully redundant electronic engine management...

Page 45: ...sult in clutch slippage CAUTION Do not use conventional a d ashless dispersant aircraft oils CAUTION Do not use oils intended primarily for diesel engines CAUTION Do not use any oil additives WARNING...

Page 46: ...Types of Fuel Unleaded automotive fuel with up to 10 maximum ethanol content meeting ASTM D4814 with minimum RON 95 minimum Anti Knock Index 91 Anti Knock Index is RON MON 2 RON is Research Octane Nu...

Page 47: ...ized distributors Coolant brands with same designation may vary from one to the other region Please contact the local distributor for a recommendation Coolant Capacity 0 93 US gallons approximate RELA...

Page 48: ...ear or damage to the underlying structure If these washers are not sufficient to ensure appropriate thread engagement or avoid thread bottoming a different grip length bolt or screw shall be used 2 20...

Page 49: ...eamers to a depth necessary to ensure washer and nut compression on the taper pin Any taper pins not meeting inspection criteria shall be removed and replaced 2 20 9 Safety Wire Safety wire shall be u...

Page 50: ...que required to run the nut down to a seated condition run on or friction drag torque shall be added to the base torque for the application and the Final Torque shall be the final requirement Final To...

Page 51: ...ns within specific inspection or maintenance tasks in this manual take precedence over the general specifications given here Thread MIN Torque Given by AC43 13 1B for Shear Type MAX Torque Given by AC...

Page 52: ...towed on any trailer The suspension on ICON s A5 trailers has been designed prototyped tested revised and retested to ensure that the shock and vibration from the trailer stay below the design limits...

Page 53: ...e and Empennage 3 19 Condition and 100 Hour Inspection Engine and Propeller 3 21 Condition and 100 Hour Inspection Avionics and Electrical 3 23 Condition and 100 Hour Inspection Operational Inspection...

Page 54: ...Installation 3 45 Cockpit Floor Board Removal 3 46 Cockpit Floor Board Installation 3 47 Cockpit Sidewall Panel Removal 3 48 Cockpit Sidewall Panel Installation 3 49 Seat Back Removal 3 50 Seat Back I...

Page 55: ...ves a list of all of the inspection tasks developed for the A5 In many cases these inspec tion tasks are useful in condition inspections or to verify the proper completion of a maintenance task RELATE...

Page 56: ...intenance on page 3 8 3 2 1 Interval Maintenance Operational Hours The inspections in the table below must be completed at the hour intervals listed Maintenance is completed at every 50 100 etc hours...

Page 57: ...i e AvGas more than 30 of the time See Engine Oil Check and Replenish on page 16 77 X NOTE IfusingprimarilyMoGas See ConditionInspectionsand100 HourInspections onpage3 9 Engine Check Clean Oil Tank S...

Page 58: ...t Balance Statement Perform a weight and balance procedure on the aircraft and record the results in the aircraft s on board POH See Empty Weight and CG Measurement on page 3 30 X NOTE A new weight an...

Page 59: ...inspection and repacked Refer to the BRS Instructions For Continued Airworthiness ICA X IPS Replace BRS Rocket Motor by date of expiry Refer to the BRS Owner s Manual X 1 The same inspection See Condi...

Page 60: ...table below must be completed at the specified hours or calendar intervals The ICON A5 airframe has a mandatory inspection and overhaul by a factory authorized indi vidual every 10 years or 2 000 hour...

Page 61: ...tisfactory result indicates an unairworthy condition After completion of the inspection the result is entered into the Aircraft Logbook either as passing airworthy or as unairworthy An airworthy aircr...

Page 62: ...e Model S N N Number Engine Total Time Airframe Total Time Propeller Model S N Owner Propeller Total Time Date Correct all unsatisfactory items prior to flight S Satisfactory U Unsatisfactory S U Comm...

Page 63: ...rigged See Inspect Roll Rigging on page 9 17 Flap hinges good condition no binding properly fastened check for play side to side and up down Flap push rods rod ends bellcranks good condition hardware...

Page 64: ...Tap Test on page 3 55 AOA ports clear left wing Inspect wiring harness routing through wing and fold tube security to spar Check wing electrical connector condition Check wingtip lights function and s...

Page 65: ...mments Fuel lines check for chafing signs of age security condition Fuel tank leak check inspect near low fuel level sensor access plate Fuel tank secure inspect rubber strap isolators and support iso...

Page 66: ...ushrods bellcranks actuator for attachment See Main Landing Gear Inspection on page 14 8 Inspect spring gear legs for cracks Check all bushings bearings for wear free play Check composite structure ne...

Page 67: ...in Landing Gear Inspection on page 14 8 Nose Gear Inspection on page 14 56 Tire Inflation Pressures on page 2 25 Wheel and Brake System Maintenance on page 14 18 Check Landing Gear Retracted Position...

Page 68: ...to frames with no delaminations Inspect rudder pedals and master cylinders for security leaks Check rudder pedal adjust mechanism for correct function See Inspect Rudder Pedal Rigging on page 9 83 In...

Page 69: ...Inspection Panels and Fairings on page 3 34 Inspect Roll Cable Tension on page 9 13 Inspect Control Cables on page 9 8 Inspect cockpit fresh air vents Inspect seats seat belts shoulder harnesses for...

Page 70: ...rior to flight S Satisfactory U Unsatisfactory S U Comments Ensure the detent pin with the REMOVE BEFORE FLIGHT flag is installed into the activation handle Inspect egress area for cracks disbonds Che...

Page 71: ...spect hinges rod ends for attachment and free play Inspect empennage skin for damage delaminations Verify no lateral play on elevator Inspect yaw cable tension See Inspect Yaw Cable Tension on page 9...

Page 72: ...AND 100 HOUR INSPECTIONS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 3 RELATED INFORMATION Inspect Pitch Rigging on page 9 44 Inspect Yaw Rigging on page 9 85 Inspect Pitch Cable Tension on page 9 42...

Page 73: ...rage gaps between airframe and firewall Check oil tank mounting brackets for security Inspect oil cooler and radiator for leaks and condition Inspect throttle control for proper travel and security Se...

Page 74: ...pection on page 16 94 Air Filter Cleanliness Inspection on page 16 43 Clean Engine Air Filter on page 16 46 Air Filter Security Inspection on page 16 44 Propeller Installation Onto Engine on page 16 1...

Page 75: ...p for function clear of debris See Check Bilge Pump Function on page 6 42 See Bilge Pump Debris Removal on page 7 6 Check wiring harness for chafing security condition See Inspect Repair and Secure Wi...

Page 76: ...UR INSPECTIONS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 3 RELATED INFORMATION Bilge Pump Debris Removal on page 7 6 Check Bilge Pump Function on page 6 42 Calibrate AOA Pressure Transducer on page...

Page 77: ...ectrical System Inspection on page 6 31 Correct all unsatisfactory items prior to flight S Satisfactory U Unsatisfactory S U Comments Perform toolbox inventory check no tools left in aircraft Visual i...

Page 78: ...______ Name _______________________________ Signature ____________________________ Date ________________________________ RELATED INFORMATION Overhaul on page 2 11 Correct all unsatisfactory items prio...

Page 79: ...ent While on Jackpoint Scales on page 3 32 3 4 1 Aircraft Dimensional Data 3 4 1 1 Aircraft Reference Locations FIGURE 3 1 AIRCRAFT REFERENCE LOCATIONS 3 4 2 Operating Weights and Loading Maximum Occu...

Page 80: ...load Minimum Load Rating of Cargo Restraints Pilot Supplied 1 000 lbf Full Usable Fuel Weight 120 lbf 20 US gal at 6 lbf per US gal Removable Side Window Weight and Fuselage Station 7 18 lbf total bot...

Page 81: ...INSPECTIONS WEIGHT AND BALANCE GENERAL 3 29 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 3 3 4 4 Center of Gravity Limits FIGURE 3 2 WEIGHT AND CG ENVELOPE LIMITS...

Page 82: ...results Check the oil dipstick to verify at least 3 17 quarts three liters of oil Service as necessary The difference between the max and the min marks is approximately 0 5 quarts 0 47 l Usable fuel...

Page 83: ...Calculation Form and perform the calculations to obtain the total empty weight and CG position VERIFICATION METHOD Fill out blank cells in table below Calculate the FS location of the CG by dividing t...

Page 84: ...rtification LSA RM Task Specific Training Required No Special Tools Required Wing Jack Point Adapter ICA009750 Parts Required None Aircraft System and Number NA Consumables None TASK INSTRUCTIONS 1 In...

Page 85: ...OH RELATED INFORMATION Weight and Balance Information on page 2 23 Weight and Balance General on page 3 27 Interval Maintenance Calendar Intervals on page 3 5 Main Landing Gear Inspection on page 14 8...

Page 86: ...quired None Parts Required None Aircraft System and Number NA Consumables None The A5 has the following access panels Aft Bulkhead Baggage Panel in the baggage compartment Water Rudder Access Panel on...

Page 87: ...Access Panel 8X Torx head 8 32 fasteners using a T15 Torx driver Air Rudder Access Panel 7X Torx head 8 32 fasteners using a T15 Torx driver Horizontal Tail Tip Access Panel 2X Torx head 6 32 fastene...

Page 88: ...oll Controls on page 9 20 Inspect Roll Cable Tension on page 9 13 Rigging Yaw Controls on page 9 87 Rigging Pitch Controls on page 9 46 Condition and 100 Hour Inspection Parachute on page 3 18 Basic P...

Page 89: ...e Installation on page 19 10 Harness Inspection Instructions on page 19 14 Extraction Rocket Inspection on page 19 23 Extraction Rocket Removal on page 19 24 Extraction Rocket Assembly and Installatio...

Page 90: ...eadset hanger light connectors 5 Remove the headliner VERIFICATION METHOD This procedure is complete when the headliner has been fully removed from the overhead console bracket RELATED INFORMATION Bag...

Page 91: ...lace 4 Push the four light control knobs onto their D shafts VERIFICATION METHOD Task is complete when headliner is installed RELATED INFORMATION Fine Fuel Filter on page 10 30 Rigging Roll Controls o...

Page 92: ...t all the way out 3 Remove the inertia reel VERIFICATION METHOD The procedure is complete when the seat belt inertia reel has been completely removed RELATED INFORMATION Baggage Sidewall Panel Removal...

Page 93: ...th new and use 020 safety wire to secure them 4 Snap the seat belt reel cover into place over the reel VERIFICATION METHOD Procedure is complete when seat belt inertia reel is installed RELATED INFORM...

Page 94: ...gage Sidewall Panel Removal on page 3 43 Fuel Level Sensor Replacement on page 6 72 Seat Back Removal on page 3 50 Main Landing Gear MLG Removal on page 14 37 Main Landing Gear MLG Installation on pag...

Page 95: ...e floor is installed RELATED INFORMATION Baggage Sidewall Panel Installation on page 3 45 Fuel Level Sensor Replacement on page 6 72 Seat Back Installation on page 3 51 Main Landing Gear MLG Removal o...

Page 96: ...4 Remove the seat belt reel associated with the sidewall panel to be removed See Seat Belt Inertia Reel Removal on page 3 39 5 Use a small cross head screwdriver or similar tool to press the center o...

Page 97: ...15 3 6 2 8 Baggage Sidewall Panel Installation Use the following procedure to install the baggage sidewall panel TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific...

Page 98: ...on page 3 40 Headliner Removal on page 3 37 Install Fuel Bladder MY17 Only on page 10 12 Rigging Roll Controls on page 9 20 Inspect Roll Cable Tension on page 9 13 Rigging Yaw Controls on page 9 87 R...

Page 99: ...ckpit floor board has been removed RELATED INFORMATION Seat Pan Removal on page 3 52 Rigging Roll Controls on page 9 20 Inspect Roll Cable Tension on page 9 13 Rigging Yaw Controls on page 9 87 Riggin...

Page 100: ...alls engage the sockets VERIFICATION METHOD Task is complete when the cockpit floor board is installed RELATED INFORMATION Seat Pan Installation on page 3 53 Rigging Roll Controls on page 9 20 Inspect...

Page 101: ...seat bottom VERIFICATION METHOD The task is complete when the steps have been completed and the cockpit sidewall panel has been removed RELATED INFORMATION Seat Back Removal on page 3 50 3 6 2 12 Coc...

Page 102: ...the following procedure to remove the seat back TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required N...

Page 103: ...8 Baggage Floor Removal on page 3 41 Remove Fuel Bladder MY17 Only on page 10 11 Seat Pan Removal on page 3 52 Main Landing Gear MLG Removal on page 14 37 Main Landing Gear MLG Installation on page 14...

Page 104: ...completed when the seat back is installed RELATED INFORMATION Fuel Level Sensor Replacement on page 6 72 Baggage Floor Installation on page 3 42 Cockpit Sidewall Panel Installation on page 3 49 Insta...

Page 105: ...e rudder pedal release cable by loosening the jam nut nearest the cable end and running it off the threaded end of the housing The cable can then be freed from the seat pan by passing the cable throug...

Page 106: ...there is no slack in the cable then tighten them against the clip 4 Locate the seat pan in the position on the support structure and align the attachment holes 5 Install the mounting hardware with Tef...

Page 107: ...hammer to tap the surface of the laminate The inspector must listen to the tapping to monitor the results audibly listening for distinct variations in the sound A clear sharp ringing sound is indicat...

Page 108: ...ly 3 5 times per second in both the good and iden tified potential defect area to note the audible difference 4 Systematically inspect the part structure tapping approximately every 0 5 1 0 inch and r...

Page 109: ...ne TASK INSTRUCTIONS 1 Remove the Aft Bulkhead Baggage Panel See Removal and Installation of Inspection Panels and Fairings on page 3 34 2 Structural Inspection a Using a flashlight and viewing mirror...

Page 110: ...3 58 INSPECTIONS STRUCTURES ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 3 RELATED INFORMATION Removal and Installation of Inspection Panels and Fairings on page 3 34...

Page 111: ...nishings See Equipment and Furnishings on page 8 1 Flight Controls See Flight Controls on page 9 1 Fuel See Fuel System on page 10 1 Fuselage and Vertical Tail See Fuselage and Vertical Tail on page 1...

Page 112: ...3 60 INSPECTIONS SYSTEM SPECIFIC INSPECTIONS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 3...

Page 113: ...ntal Tail 4 2 Seawings Platforms 4 2 Landing Gear System 4 2 Wheels and Brakes 4 3 Rinse After Salt Water Operations 4 4 Overall Exterior Rinse 4 5 Interior Rinse 4 6 Wing Fold Rinse 4 7 Horizontal Ta...

Page 114: ...ly installed and the second to detect the latch is secured The removable tip latches are located on the underside of the horizontal tail and are placarded to show operation 4 1 3 Seawings Platforms Th...

Page 115: ...e toe brakes can be used collectively to slow the aircraft when on the ground or individually to steer the aircraft Hydraulic Parking Brake The braking system features a hydraulic parking brake access...

Page 116: ...on Landing in fresh water should not be considered a substitute for a thorough rinse as described in this section Any visible salt should be rinsed off as soon as practical Level 1 Aircraft used in fr...

Page 117: ...o bearings or pry apart joints CAUTION Do not direct water into the pitot tube or static and AOA ports TASK INFORMATION Type of Maintenance Line Level of Certification Owner Pilot Task Specific Traini...

Page 118: ...his task describes how to perform a fresh water rinse on the interior of the aircraft including the bilge pump after salt water operations TASK INFORMATION Type of Maintenance Line Level of Certificat...

Page 119: ...to rinse the water rudder bellcrank for one minute 7 Replace inspection panel Run bilge pump until bilge is empty VERIFICATION METHOD Task is done when all steps are complete and bilge is empty RELATE...

Page 120: ...wel to dry surfaces Leave wings extended until all surfaces have dried VERIFICATION METHOD Task is done when steps are complete and all surfaces have dried RELATED INFORMATION Rinse After Salt Water O...

Page 121: ...ons on page 4 4 4 2 5 Salt Away Rinse Use this task to perform a Salt Away rinse according to the corrosion prevention schedule See Related Information TASK INFORMATION Type of Maintenance Line Level...

Page 122: ...Level of Certification Owner Pilot Task Specific Training Required No Special Tools Required None Parts Required No Aircraft System and Number Consumables None TASK INSTRUCTIONS 1 Apply corrosion inhi...

Page 123: ...to the brake disk or pads g Water rudder hinge sector and retraction cable h Air rudder lower hinge and drive lugs i All HT tip joint metal parts j All wing fold metal parts k Canopy latch VERIFICATI...

Page 124: ...lack 1 2 in 16 mil TASK INSTRUCTIONS 1 Remove existing VHB from component and attaching surface When removing a component attached with VHB tape gradually soften and loosen the tape with isopropyl alc...

Page 125: ...ces ICA000500 VORTEX GENERATOR AND FENCE INSTL FUSELAGE ICA009726 VORTEX GENERATOR 2 3 INJ MLD WHITE ICA009210 FENCE FLAP ROOT RH ICA009211 FENCE FLAP ROOT LH ICA000501 STALL STRIP INSTL ICA009265 STA...

Page 126: ...4 14 STRUCTURES USE OF VHB TAPE FOR INSTALLATIONS AND REPAIRS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 4...

Page 127: ...Chapter 5 DOORS AND WINDOWS 5 1 CHANGE C0 ICON A5 MAINTENANCE MANUAL CHAPTER 5 DOORS AND WINDOWS Doors and Windows Description 5 2...

Page 128: ...attachment restraint and panels removable and or not hinged used for inspection and or equipment access Windows include the windshield canopy consisting of transparency frame and removable side window...

Page 129: ...iagram Instrument Lighting 6 19 System Wiring Diagram Instrument Signals 6 20 System Wiring Diagram Interior Lighting 6 21 System Wiring Diagram Landing Gear 6 22 System Wiring Diagram Mode C 6 25 Sys...

Page 130: ...7 Landing and Taxi Lights Description 6 57 Landing and Taxi Lights Diagram Schematic 6 57 Maintenance Instructions 6 58 Remove Landing and Taxi Lights 6 58 Install Landing and Taxi Lights 6 60 Dome Li...

Page 131: ...n automatic reset circuit breaker The fuse panel and circuit breaker are located in the overhead console There are 4 fuse ratings 5A 7 5A 15A and 20A Also there is a minimum of 3 spare fuses of each r...

Page 132: ...ON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 Electrical System Wiring Diagrams System wiring diagrams for all of the aircraft systems including control sticks ELT engine lighting flaps fuel system...

Page 133: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 5 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 1 System Wiring Diagram Bilge...

Page 134: ...6 6 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 2 System Wiring Diagram Control Sticks Pitch Trim...

Page 135: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 7 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 3 System Wiring Diagram ELT...

Page 136: ...6 8 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 4 System Wiring Diagram Engine Interface...

Page 137: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 9 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6...

Page 138: ...6 10 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6...

Page 139: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 11 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6...

Page 140: ...6 12 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 5 System Wiring Diagram Exterior Lights...

Page 141: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 13 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6...

Page 142: ...6 14 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 6 System Wiring Diagram Flaps...

Page 143: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 15 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 7 System Wiring Diagram Fuel...

Page 144: ...6 16 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 8 System Wiring Diagram GPS...

Page 145: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 17 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 9 System Wiring Diagram Heater...

Page 146: ...6 18 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 10 System Wiring Diagram Hour Meter...

Page 147: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 19 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 11 System Wiring Diagram Instrument Lighting...

Page 148: ...6 20 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 12 System Wiring Diagram Instrument Signals...

Page 149: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 21 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 13 System Wiring Diagram Interior Lighting...

Page 150: ...6 22 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 14 System Wiring Diagram Landing Gear...

Page 151: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 23 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6...

Page 152: ...6 24 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6...

Page 153: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 25 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 15 System Wiring Diagram Mode C...

Page 154: ...6 26 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 16 System Wiring Diagram Outlets...

Page 155: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 27 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 17 System Wiring Diagram VHF...

Page 156: ...6 28 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6...

Page 157: ...ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS 6 29 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 6 2 18 System Wiring Diagram Water Rudder...

Page 158: ...6 30 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 6 6 2 19 System Wiring Diagram Wing Tip Switches...

Page 159: ...ired No Special Tools Required None Parts Required None Aircraft System and Number 03 Electrical System Consumables None TASK INSTRUCTIONS 1 Remove 4 Torx head 10 32 fasteners to remove the Aft Bulkhe...

Page 160: ...s 0 VDC Battery charging fuse blown Replace 15A fuse located forward of the positive charging terminal on the positive charging wire Battery capacity below 85 of rating below 20 4 AH Battery beyond se...

Page 161: ...ectrical System Consumables None TASK INSTRUCTIONS 1 Locate the ignition switch Unscrew the pilot facing cap to release the ignition switch from the left hand crossbeam Discard cap 2 Reach behind the...

Page 162: ...the ignition switch to secure it to the left hand crossbeam VERIFICATION METHOD The task is complete when the switch is secured to the left hand crossbeam and verified to function correctly by turning...

Page 163: ...on the engine The engine wire harness must have minimum no touch clearance from any corner or sharp edge of the areas as per installed state 3 If chaffing or nick damage to insulation of wires is foun...

Page 164: ...s Mat AGM battery that is part of Concorde aircraft batteries It produces 350 cold cranking amps CCA and weights 23 5 lb Make sure to use an AGM compatible charging system for the battery AGM batterie...

Page 165: ...ument Panel Cover See Right Instrument Panel Top Panel Removal on page 8 17 2 Disconnect the cabling from the negative battery terminals 3 Disconnect the cabling from the positive battery terminals 4...

Page 166: ...nd function correctly RELATED INFORMATION Right Instrument Panel Top Panel Removal on page 8 17 Right Instrument Panel Top Panel Installation on page 8 18 Nose Landing Gear NLG Leg Assembly Removal on...

Page 167: ...tery 4 Remove the multimeter from the battery charging terminals 5 Verify that your charging unit is OFF WARNING Make sure to use an AGM compatible charging system for the battery Because AGM batterie...

Page 168: ...charging clamps from the aircraft battery charging terminals 12 Use a multimeter to verify that the battery voltage is at or above 12 6 VDC 13 Replace the red and black terminal caps See Figure 6 3 V...

Page 169: ...he hull It is located near the hull step beneath the fuel tank It pumps any water from the hull overboard via a port located on the left side of the fuselage above the left Seawings platform This allo...

Page 170: ...5 BILGE PUMP INSTALLATION AND OUTLET ROUTING 6 6 3 Inspection Instructions 6 6 3 1 Check Bilge Pump Function The following section includes the information necessary to check the function of the bilg...

Page 171: ...out NOTE A positive pitch attitude on the aircraft ensures optimum cleaning This can be obtained by performing the procedure while parked on an incline preferred lifting the nose or pushing down on th...

Page 172: ...k mounting structure disconnect the bilge pump hose from the pump by loosening the hose clamp and pulling the hose off the pump s barb 4 Cut the cable tie attaching the pump to the carbon saddle 5 Twi...

Page 173: ...tem and Number 03 Electrical Systems Consumables Sil Poxy Silicone Adhesive TASK INSTRUCTIONS 1 Remove any adhesive residue from the bilge pump mounting flange 2 Remove bottom strainer from bilge pump...

Page 174: ...FIGURE 6 7 LOCK BOTTOM STRAINER 5 Secure the pump to the mounting flange with a TY528MX cable tie as shown See Figure 6 8 FIGURE 6 8 SECURE THE PUMP TO MOUNTING FLANGE 6 Apply Sil Poxy adhesive aroun...

Page 175: ...es normally 10 Install the fuel tank mounting structure if needed 11 Install the fuel tank See Install Fuel Bladder MY17 Only on page 10 12 VERIFICATION METHOD The task is complete when both the bilge...

Page 176: ...y loosening the hose clamp and pulling the hose off the pump s barb 3 Detach the pump body from the bottom strainer by depressing the lock bottom and turning counter clockwise 4 Remove the pump body l...

Page 177: ...ALANT 2000 B SILICONE ELASTOMER ONE COMPONENT TASK INSTRUCTIONS 1 Clean the bilge area of any sand stones or other debris 2 Remove the lower screen from the bilge pump and set it aside NOTE It will no...

Page 178: ...nter of the flat section Attach the bilge pump hose to the pump barb fitting and secure with a 3806 CLAMP as shown below Route the hose as indi cated below Slide one end of the hose onto the bulkhead...

Page 179: ...OSE 5 For the clamp on the bulkhead fitting in the pilot side fuselage skin clock the clamp such that the screw housing is fully within the following approximate zone make sure there is a minimum clea...

Page 180: ...LAMP ORIENTATION 6 Connect D9009J connector on bilge pump to D9009P connector on main wire harness 7 Test that the bilge pump operates normally 8 Install the fuel tank See Install Fuel Tank MY18 on pa...

Page 181: ...ains a set of leading edge and trailing edge position and strobe lights 6 7 2 Wing Tip Lights Diagram Schematic 6 7 3 Maintenance Instructions 6 7 3 1 Removal of Wing Tip Lights These instructions sho...

Page 182: ...the O ring remains on it 2 Detach light from aircraft and disconnect the light s wire harness connectors a Disconnect D90002J1 and D9002P2 on LIGHT POSITION STROBE LE LH from D9002P1 and D90002J2 on a...

Page 183: ...moved from the aircraft Use Installation of Wing Tip Lights to reinstall RELATED INFORMATION Installation of Wing Tip Lights on page 6 55 6 7 3 2 Installation of Wing Tip Lights These instructions sho...

Page 184: ...o installation 3 Connect the light s wire harness connectors a For the LH Trailing Edge light connect D9003P on light to D9003J on aircraft wire harness b For the RH Trailing Edge light connect D9007P...

Page 185: ...Lights 6 8 1 Landing and Taxi Lights Description Each aircraft has landing and taxi lights on the left hand and right hand side of the front of the aircraft The switch for the landing and taxi lights...

Page 186: ...8 3 1 Remove Landing and Taxi Lights Use the following instructions to remove the landing and taxi lights TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Trainin...

Page 187: ...ee Left Instrument Panel Top Panel Removal on page 8 19 2 Unplug D9033P connector on main wire harness from receptacle on LH light 3 Unplug D9034P connector on main wire harness from receptacle on RH...

Page 188: ...e of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required 13 INCH POUND TORQUE WRENCH Parts Required LIGHT TAXI AND LANDING RH LIGHT TAXI AND LANDIN...

Page 189: ...on the landing and taxi lights switch in the radio bezel to verify lights are working correctly VERIFICATION METHOD This task is done when the landing and taxi lights are installed and working RELATED...

Page 190: ...ENANCE MANUAL CHANGE C2 CHAPTER 6 6 9 Dome Light Switch 6 9 1 Dome Light Switch Description The dome light switch is a 30A SPST single pole single throw switch that controls the dome light in the over...

Page 191: ...ELECTRICAL SYSTEM DOME LIGHT SWITCH 6 63 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 FIGURE 6 17 OVERHEAD CONSOLE AND DOME LIGHT SWITCH...

Page 192: ...ing Required No Special Tools Required None Parts Required None Aircraft System and Number 03 Electrical System Consumables None TASK INSTRUCTIONS 1 Remove the overhead console bezel See Overhead Cons...

Page 193: ...aintenance Line Level of Certification A P Task Specific Training Required No Special Tools Required None Parts Required R13 133A 01 SWITCH SPST 30A Aircraft System and Number 03 Electrical System Con...

Page 194: ...EW DOWN OF OVERHEAD CONSOLE 3 Reinstall the console bezel See Overhead Console Component Replacement on page 13 15 VERIFICATION METHOD Turn the master switch on and verify that the dome light switch c...

Page 195: ...sensor utilizes the annunciator panel to alert the pilot if the fuel pressure is abnormal 6 10 2 Fuel Pressure Sensor Diagram Schematic FIGURE 6 19 FUEL PRESSURE SENSOR LOCATION 6 10 3 Maintenance In...

Page 196: ...ctrical System Consumables None TASK INSTRUCTIONS 1 Remove headliner See Headliner Removal on page 3 37 2 Turn fuel shutoff valve to the OFF position 3 Disconnect D9036P on fuselage wire harness from...

Page 197: ...task is completed when the fuel pressure sensor has been removed RELATED INFORMATION Headliner Removal on page 3 37 6 10 3 2 Install Fuel Pressure Sensor Use the following instructions to install the...

Page 198: ...reads of PRESSURE SENSOR with ISOPROPYL ALCOHOL MEK OR ACETONE 2 Apply THREADLOCKER to threads of the PRESSURE SENSOR Install PRESSURE SENSOR 2 to 3 turns past finger tight into the fuel pressure sens...

Page 199: ...Level Sensor Description The fuel level sensor is mounted into the tank through the fuel tank access panel It is connected to T9026 and T9028 ring terminals with washers and bolts and connected to D90...

Page 200: ...SOR FUEL SENSOR GASKET FUEL TANK ACCESS PLATE GASKET Aircraft System and Number 03 Electrical System Consumables TY24MX ZIP TIE LOCTITE 243 THREADLOCKER GASKET SEALANT TASK INSTRUCTIONS 1 Remove the r...

Page 201: ...FUEL LEVEL SENSOR 6 73 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 6 FIGURE 6 22 REMOVE FUEL TANK ACCESS PLATE 6 Remove the 4 6C37MTT3 SCREW on CLAMP BRACKETS to release the fuel level sensor from In...

Page 202: ...LAMP BRACKETS 7 Remove the bolts attaching the fuel level sensor to the FUEL TANK ACCESS PLATE The sensor is attached to the FUEL TANK ACCESS PLATE using six MS35307 BOLT threaded into blind fasteners...

Page 203: ...check its condition Replace if necessary 9 Install new fuel level sensor and its gasket onto the FUEL TANK ACCESS PLATE Torque the five MS35307 BOLT in star shaped pattern to 40 in lbs each See Figure...

Page 204: ...t lines between bolt holes and half crescents to the interior around the bolt holes Allow sealant to sit for 5 minutes after being applied to gasket surfaces before placing gasket onto fuel tank 12 Re...

Page 205: ...he fuel tank verify the low level light goes out c Add two more gallons of fuel into the fuel tank and verify fuel level sensor reads about 5 gallons 18 Secure fuel level sensor wire harness to zip ti...

Page 206: ...t See Seat Back Installation on page 3 51 21 Install the right baggage floor See Baggage Floor Installation on page 3 42 VERIFICATION METHOD Step 16 operates as the verification method for this task R...

Page 207: ...PTER 7 ENVIRONMENTAL CONTROL UTILITY SYSTEMS Environmental Control System Description 7 2 Cabin Heater 7 3 Cabin Heater Description 7 3 Inspection Instructions 7 3 Heater Fan and Core Removal 7 3 Heat...

Page 208: ...CHAPTER 7 7 1 Environmental Control System Description Those units and components which furnish a means of heating cooling and or ventilate the internal volumes of the fuselage Includes cabin heating...

Page 209: ...ICON Aircraft does not allow for any repairs to be made to the cabin heater without prior consent Any cabin heater repairs needed must be coordinated and approved by ICON through the Major Repair and...

Page 210: ...in place support it with a stiff wire or cable tie so as not to put loads into the coolant lines other wise it can now be removed VERIFICATION METHOD The task is complete when the heater core has bee...

Page 211: ...four NAS1149CN832R washers securing the heater fan and core to the composite bracket torquing each to 7 in lbf 4 Tighten the two heater core B nuts to 75 125 in lbf holding the hex on the core with a...

Page 212: ...stems Consumables None TASK INSTRUCTIONS 1 Remove the 4 Torx 20 10 32 thread flat head screws of the right baggage floor panel 2 Remove the right baggage floor panel See Baggage Floor Removal on page...

Page 213: ...nter Console Bucket Installation 8 8 Throttle Handle and Bezel Removal 8 10 Throttle Handle and Bezel Installation 8 13 GPS Mount and Radio Stack Bezel Removal 8 15 GPS Mount and Radio Stack Bezel Ins...

Page 214: ...n Those fixed and removable items of equipment and furnishings contained in the cockpit and baggage compartment Typical parts are seats shoulder harnesses seat belts instrument panel and console compo...

Page 215: ...aft System and Number 05 Equipment and Furnishings Consumables None TASK INSTRUCTIONS 1 Remove the baggage floors and seat back panel on the side of the seat belt to be removed See Baggage Floor Remov...

Page 216: ...INTENANCE MANUAL CHANGE C1 CHAPTER 8 FIGURE 8 1 CO PILOT SIDE SHOWN 4 Use a 1 2 wrench to remove the bolt securing the inboard end of the seat belt where it attaches to the inboard keel structure it i...

Page 217: ...loseout and baggage floors See Seat Pan Installa tion on page 3 53 See Seat Back Installation on page 3 51 See Baggage Floor Installation on page 3 42 VERIFICATION METHOD Procedure is complete when st...

Page 218: ...ANUAL CHANGE C1 CHAPTER 8 None TASK INSTRUCTIONS 1 Remove 2X Screws which secure the FWD edge of the center console bucket Retain all fastening hardware See Figure 8 3 FIGURE 8 3 FWD EDGE BUCKET SCREW...

Page 219: ...UAL CHAPTER 8 FIGURE 8 4 CENTER ARMREST SCREWS 3 Lift the center console bucket disconnect the electrical connections and remove Label the wires for later installation The connections are cigarette li...

Page 220: ...ter console is removed RELATED INFORMATION Inspect Yaw Cable Tension on page 9 80 Rigging Yaw Controls on page 9 87 Rigging Pitch Controls on page 9 46 GPS Mount and Radio Stack Bezel Removal on page...

Page 221: ...6 a Connector D9063J in bucket assembly connects to connector D9063P on fuselage wiring harness b Terminal T9117 on fuselage wiring harness connects to positive terminal on 12V c Terminal T9119 on fus...

Page 222: ...e is installed in the aircraft RELATED INFORMATION Inspect Yaw Cable Tension on page 9 80 Rigging Yaw Controls on page 9 87 Rigging Pitch Controls on page 9 46 GPS Mount and Radio Stack Bezel Installa...

Page 223: ...the handle grips using a 9 64 hex wrench Separate the two halves of the handle to remove it from the throttle lever Retain all fastening hardware and handle components See Figure 8 7 FIGURE 8 7 THROTT...

Page 224: ...CHAPTER 8 FIGURE 8 8 STANDOFF REMOVAL 4 Remove throttle bezel along with the hour meter connectors T9114 and T99105 Label each wire to ease reinstallation The forward part of the bezel has two indexi...

Page 225: ...when the throttle handle and bezel is removed from the aircraft RELATED INFORMATION Rigging Yaw Controls on page 9 87 Rigging Pitch Controls on page 9 46 GPS Mount and Radio Stack Bezel Removal on pag...

Page 226: ...onnect electrical connections as follows refer to Figure 8 10 a Connect T9114 terminal on fuselage wiring harness to the positive terminal on hour meter b Connect T9105 terminal on fuselage wiring har...

Page 227: ...unt and Radio Stack Bezel Installation on page 8 16 8 2 6 GPS Mount and Radio Stack Bezel Removal Use the following procedure to remove the GPS mount and Radio stack bezel TASK INFORMATION Type of Mai...

Page 228: ...isconnect transponder harness D9068P and the Radio harness D9063P Disconnect the static line to the transponder control head to completely release radio stack bezel VERIFICATION METHOD The procedure i...

Page 229: ...ezel torquing all to 13 in lbf VERIFICATION METHOD The procedure is complete when the GPS mount and radio stack bezel has been installed RELATED INFORMATION Center Console Bucket Installation on page...

Page 230: ...le crosshead driver Remove the 8 32 screws at the forward right side and at aft left corner of the right instrument top panel with a T15 Torx driver Remove the right instrument top panel VERIFICATION...

Page 231: ...tions 3 Install Throttle Handle and Bezel See Throttle Handle and Bezel Installation on page 8 13 4 Install the Center Console Bucket See Center Console Bucket Installation on page 8 8 5 Install the G...

Page 232: ...with hook and loop tape 4 Remove GPS mount and Radio stack bezel See GPS Mount and Radio Stack Bezel Removal on page 8 15 5 Remove the ICA008624 cluster hood See Replace Instrument Panel Gauge on page...

Page 233: ...l of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 05 Equipment and Furnishing Consumables LOCTITE 243 TASK INSTRUC...

Page 234: ...e 11 4 Nose Landing Gear NLG Leg Assembly Installation on page 14 62 Install Landing and Taxi Lights on page 6 60 8 2 12 Instrument Panel Center Spine Removal and Installation Use the following proced...

Page 235: ...e Right Instrument Panel Top Panel Removal on page 8 17 3 Remove 4x screws securing handhold from top of center console Retain for reinstallation FIGURE 8 11 REMOVE HANDHOLD SCREWS 4 Remove two screws...

Page 236: ...Figure 8 12 torque screws to 13 in lbs 6 Install Handhold using four screws as shown in Figure 8 11 torque screws to 13 in lbs 7 Install right instrument panel top panel See Right Instrument Panel To...

Page 237: ...17 Maintenance Instructions 9 20 Rigging Roll Controls 9 20 Remove Roll Cables 9 28 Install Roll Cables 9 32 Roll Trim Tab 9 35 Roll Trim Tab Description 9 35 Roll Trim Tab Diagram Schematic 9 35 Ins...

Page 238: ...s Description 9 65 Flap Controls Diagram Schematic 9 65 Inspection Instructions 9 65 Inspect Flap Rigging 9 65 Rigging Flap Controls 9 67 Maintenance Instructions 9 71 Remove Flap Actuator 9 71 Instal...

Page 239: ...either direction by changing the position of the ailerons The aft to forward movement of the control stick changes the pitch of the aircraft by adjusting the pitch of the elevator Applying foot pressu...

Page 240: ...ONTROLS DIAGRAM SCHEMATIC ICON A5 MAINTENANCE MANUAL CHANGE C3 CHAPTER 9 9 2 Diagram Schematic FIGURE 9 1 FLIGHT CONTROL DIAGRAM Flap Controls Roll Controls Rudder Pedals Pitch Controls Yaw Controls C...

Page 241: ...Rudder Pedal Adjustment Mechanism The following section contains information needed to inspect the rudder pedal adjust mechanism for correct function TASK INFORMATION Type of Maintenance Line Level o...

Page 242: ...NTENANCE MANUAL CHANGE C3 CHAPTER 9 FIGURE 9 2 RUDDER PEDAL LATCH LOCATIONS UNDER PILOT AND CO PILOT SEATS TASK INSTRUCTIONS 1 Remove the floorboard immediately in front of the pilot seat See Cockpit...

Page 243: ...ugh the floor are free to operate and the pedals move freely 7 Pull the lever again and unlock the locking mechanism 8 Push with heel on heel strike in between the pedals on floor 9 Confirm pedal asse...

Page 244: ...corrosion kinks and broken strands TASK INSTRUCTIONS 1 Inspect cables for broken strands Any cable assembly that has at least one broken wire strand located in a critical fatigue area must be replaced...

Page 245: ...he inboard rod end of the inboard pushrod on the wing and the lower roll control cable terminal at the bottom of the roll socket at the wing fold joint a If there is evidence of wear on the rod end or...

Page 246: ...OLS FLIGHT CONTROL SYSTEM GENERAL MAINTENANCE ICON A5 MAINTENANCE MANUAL CHANGE C3 CHAPTER 9 RELATED INFORMATION Condition and 100 Hour Inspection Forward Fuselage and Hull on page 3 16 Remove Roll Ca...

Page 247: ...e roll of the aircraft by converting the left right user input at the control stick and changing the pitch of the ailerons A series of cables and pulleys are used to make this possible Proper tensions...

Page 248: ...FUSELAGE ROLL SYSTEM DETAILED VIEW Upper Roll Cable Tensiometer Location BL38 Clamshell Rig Pin Hole Uppe Tensi RH LH Lower Roll Cable Turnbuckles RH LH Lower Roll Cables Tensiometer Location FWD Pit...

Page 249: ...l Cable Tension This section contains instructions to check roll cables for correct tensions TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No...

Page 250: ...3 52 Retain all fastening hardware 3 Remove the baggage floor boards See Baggage Floor Removal on page 3 41 Retain all fastening hardware 4 Remove seatbelt cover left hand and right hand baggage side...

Page 251: ...NTROL STICK RIG PIN LOCATION 7 Fold both aircraft wings and install a 1875in diameter rig pins at both of the wing socket bell crank See Figure 9 11 FIGURE 9 11 WING SOCKET BELLCRANK RIG PIN LOCATION...

Page 252: ...t Inertia Reel Installation on page 3 40 See Baggage Sidewall Panel Installation on page 3 45 See Headliner Installation on page 3 38 See Removal and Installation of Inspection Panels and Fairings on...

Page 253: ...wall Panel Removal on page 3 43 Baggage Sidewall Panel Installation on page 3 45 Headliner Removal on page 3 37 Headliner Installation on page 3 38 Inspect Roll Rigging on page 9 17 Removal and Instal...

Page 254: ...t the base of the control sticks as shown in Figure 9 13 at the specified force If not within specified force adjust the length of the secondary stop bolts using NAS1149C0363R washers If a finer adjus...

Page 255: ...stop contact at outboard roll bellcrank should be heard Record level reading at maximum TEU travel the weight of the level should be enough to remove play without hand pressure RESULT Reg No of Aircra...

Page 256: ...rol system following disassembly maintenance and reassembly of the roll cable circuit TASK INFORMATION Type of Maintenance Line Level of Certification A P Task Specific Training Required No Special To...

Page 257: ...e Headliner Removal on page 3 37 If headliner cannot be removed without removal of overhead console temporary removal is permitted ICA008925 BUSHING FLANGE 250X 100X 032 4 ICA008926 BUSHING FLANGE 250...

Page 258: ...that show excessive wear or damage must be replaced with new components Refer to table for compo nent list 7 Install 250 diameter rig pin through the center console and forward pitch sector prior See...

Page 259: ...ATIONS CONTROL STICK RIG PIN HOLE 9 Fold both aircraft wings and install 2X 1875 in diameter rig pins at both of the wing socket bell crank See Figure 9 16 FIGURE 9 16 RIG PIN LOCATIONS LH SHOWN RH OP...

Page 260: ...FIGURE 9 17 TENSIOMETER AND CABLE ADJUSTMENT LOCATIONS 11 Install turnbuckle clips into turnbuckles connecting control cables to control sticks ICA012104 clip goes on the rod end side and the MS21256...

Page 261: ...ling edge with flap trailing edge within 0 02 in Once adjusted torque push tube jam nut to 60 in lbs Torque through bolt and locking nut to 20 in lbs 16 Secure a digital protractor to the top surface...

Page 262: ...ve been installed a 2X Wing socket bellcrank rig pins b 2X Outboard roll bellcrank rig pins c Control stick rig pin 18 Ensure ailerons maximum travel limits are set as specified a Trailing Edge Down 1...

Page 263: ...e Baggage Floor Instal lation on page 3 42 23 Install seat back and seat pan using hardware retained during removal See Seat Back Installa tion on page 3 51 See Seat Pan Installation on page 3 53 24 I...

Page 264: ...3 40 Baggage Sidewall Panel Removal on page 3 43 Baggage Sidewall Panel Installation on page 3 45 Headliner Removal on page 3 37 Headliner Installation on page 3 38 Inspect Roll Rigging on page 9 17...

Page 265: ...eadliner See Headliner Removal on page 3 37 6 De tension the affected lower flight control cable by removing the safety wire or turnbuckle clips and loosen the turnbuckle located at the torque tube en...

Page 266: ...ECTION POINTS 8 There are two methods to remove the cable from the aircraft either are acceptable a Remove the three pully pivot bolts b Remove the two safety pins on each pully bracket 9 Remove the w...

Page 267: ...les by removing the safety pins from the turn buckle 11 Disconnect the upper roll cable at the roll socket and the turnbuckle Ensure that the cable is held while disconnecting the turnbuckle 12 Carefu...

Page 268: ...task to install the upper and lower control cables TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required Flight Control Cab...

Page 269: ...install the bolts and torque to 48 in lb If the safety pins were removed re install with a new MS25665 151 cotter pins See Roll Pulley Exploded Views on page 9 33 FIGURE 9 25 ROLL PULLEY EXPLODED VIEW...

Page 270: ...s while routing the cable Snaking the cable is permissible FIGURE 9 26 ROUTING UPPER CONTROL CABLE 9 Connect the upper control cable at the upper attachment point of the roll socket using new locking...

Page 271: ...l Trim Tab 9 5 1 Roll Trim Tab Description The Roll Trim Tab enables the A5 to have zero roll input at the control stick for straight and level flight Roll trim can be adjusted by removal and installa...

Page 272: ...None TASK INSTRUCTIONS 1 Remove the existing roll trim tab from the aircraft if installed See Remove Roll Trim Tab on page 9 37 2 Verify that there is no water in either wing tip Load the aircraft to...

Page 273: ...aintenance Instructions 9 5 4 1 Remove Roll Trim Tab Use these instructions to remove the roll trim tab and clean the leftover adhesive residue from the aileron control surface TASK INFORMATION Type o...

Page 274: ...removed the surface cleaned and the underlying attachment surface on the aileron is not damaged RELATED INFORMATION Install Roll Trim Tab on page 9 38 Determine Roll Trim Tab Length on page 9 36 9 5 4...

Page 275: ...e of the VHB tape and stick it to one leg of the tab FIGURE 9 27 RIGHT AILERON SHOWN 3 Trim the tape flush with the edges of the footprint of the tab 4 Trim both ends of the leg of the tab without tap...

Page 276: ...itch control system is composed of a series of cables pulleys pushrods and FWD AFT pitch sectors Input at the control stick in the FWD AFT direction results in an output at the elevator control surfac...

Page 277: ...FLIGHT CONTROLS PITCH CONTROLS 9 41 CHANGE C3 ICON A5 MAINTENANCE MANUAL CHAPTER 9 FIGURE 9 29 PITCH SECTOR FWD DETAIL FIGURE 9 30 PITCH SECTOR FWD DETAIL...

Page 278: ...s Required None Aircraft System and Number 06 Flight Controls Consumables None TASK INSTRUCTIONS 1 Remove left hand and right hand forward and main cockpit floor boards See Cockpit Floor Board Removal...

Page 279: ...IN LOCATION 5 From within the AFT bulkhead baggage access window use a tensiometer cable thickness 1 8 in to measure elevator cable tension Refer to figure 2 Ensure they are within 18 33 lbf of tensio...

Page 280: ...ers calibration card to correctly read cable tension for the cable diameter RELATED INFORMATION Condition and 100 Hour Inspection Aft Fuselage and Empennage on page 3 19 9 6 3 2 Inspect Pitch Rigging...

Page 281: ...ntal tail tips take the average if left and right align differently Set the Alt Ref function of the level 3 Have a helper move the control stick to lower the elevator trailing edge down hard against t...

Page 282: ...red Aircraft Cable Tensiometer Parts Required As needed based upon inspections and condition of parts Contact ICON Aircraft for assistance as needed A list of part numbers in the elevator cable system...

Page 283: ...val on page 3 52 Retain all fastening hardware MS20392 1R4 3 PIN STRAIGHT HEADED DRILLED SHANK 1 MS21043 4 NUT SLFLKG RDC HEX CRES 250 28 2 MS21251 B5L TURNBUCKLE BODY CLIP LKG BRASS 156X 250 28X4 00...

Page 284: ...Retain all fastening hard ware 8 Inspect all components within the pitch circuit for excessive wear Any components that show excessive wear or damage must be replaced with new components 9 Install 25...

Page 285: ...IONS 13 Remove rig pin in the aft pitch sector in vertical tail See Figure 9 33 14 Install horizontal tail and removable HT tips See Horizontal Tail Removal and Installation on page 12 6 See Horizonta...

Page 286: ...e rod end as necessary so that the rod end lines up with the elevator control horn while the elevator is in the 2 position This will be the initial adjustment If necessary final adjustments will be ma...

Page 287: ...ns have been met install the hardware to connect the pushrod to the elevator control horn Torque the pushrod jam nut to 60 inlbs Torque the bolt to 20 inlbs 25 Ensure that there is no rubbing binding...

Page 288: ...e 3 40 Baggage Sidewall Panel Removal on page 3 43 Baggage Sidewall Panel Installation on page 3 45 Headliner Removal on page 3 37 Headliner Installation on page 3 38 Inspect Roll Rigging on page 9 17...

Page 289: ...tuator is a linear actuator It moves a pushrod connected to the pitch trim tab 9 7 2 Pitch Trim Actuator Diagram Schematic FIGURE 9 39 PITCH TRIM ACTUATOR ASSEMBLY 9 7 3 Maintenance Instructions 9 7 3...

Page 290: ...ve elevator from the aircraft carefully allowing the trim push rod to slide through the elevator 8 Remove the trim actuator push rod from the trim actuator by removing the cotter pin clevis pin and wa...

Page 291: ...ng its function TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required ICA006821 TRIM ACTUATOR Aircraft S...

Page 292: ...the D9017P connector in the horizontal tail and installing the four cross head screws as shown Torque to 14 in lbf 3 If pushrod needs to be replaced for wear assemble the pushrod ICA007117 helical coi...

Page 293: ...by carefully guiding the elevator trim tab pushrod through the elevator and securing the elevator outboard hinges with four screws right side shown repeat for left side Torque screws to 26 in lbf 6 In...

Page 294: ...9 7 Install the elevator push tube rod end hardware as shown and torque to 20 in lbf 8 Connect trim tab pushrod to the trim tab as shown by installing the pin MS20392 1R11 washer NAS1149CN432R and cot...

Page 295: ...MAINTENANCE MANUAL CHAPTER 9 9 Install the horizontal tail tips VERIFICATION METHOD Check and make adjustments as needed to the pitch trim rigging See Inspect Pitch Trim Tab Rigging on page 9 61 RELAT...

Page 296: ...the secondary flight controls it is a small surface connected to the trailing edge of the elevator This trim tab can only be controlled from the top of the LH control stick The trim tab is adjusted to...

Page 297: ...TCH TRIM TAB SECTION VIEW 9 8 3 Inspection Instructions 9 8 3 1 Inspect Pitch Trim Tab Rigging The following section contains the information required to perform an inspection of the pitch trim tab ri...

Page 298: ...inclinometer to the top of the trim tab surface with double sided tape Ensure that its long axis is perpendicular to tab hinge line and that it does not interfere with tab operation 4 Operate the tri...

Page 299: ...ols Consumables None TASK INSTRUCTIONS 1 Hold the elevator so that its trailing edge aligns with the horizontal tail tips take the average if left and right align differently throughout this procedure...

Page 300: ...due to free play with a scale at the TE of the pitch trim tab 7 Inspect the maximum diameter of the pitch trim tab control horn hole using a caliper 8 Remove inclinometer and any tape used to secure i...

Page 301: ...the pilot turns the knob to move the flaps the linear actuator moves a system of pushrods and bellcranks which in turn moves the wing flaps down The flaps return to the zero position using gas struts...

Page 302: ...ct 0 flap and verify flaps are in line with the center wing trailing edge 020 4 Select 0 flap position and secure digital level to flap surface with its long axis perpendicular to flap hinge line 5 Al...

Page 303: ...Removal on page 14 37 Main Landing Gear MLG Installation on page 14 38 Flap Surface Installation on page 17 20 Rigging Flap Controls on page 9 67 9 9 3 2 Rigging Flap Controls Use the following proced...

Page 304: ...2 EA ICA011314 PIN BELL CRANK FLAP 1 EA ICA009500 NUT SPANNER 75X16 FLAP INTERCONNECT 2 EA ME000683 A BELLCRANK FLAP SUBASSY 1 EA ME000684 A CABLE FLAP LH SUBASSY 1 EA ME000685 A CABLE FLAP RH SUBASSY...

Page 305: ...on might be different for accessibility 3 Flap System Rigging Process See Figure 9 43 a Set wings to the folded configuration per POH wing fold operation b Adjust fuselage flap pin to achieve 200 030...

Page 306: ...rank contacts the up stop and the flap trailing edge lines up with the trailing edge of the center wing as described in Figure 9 44 Refer to Figure 9 43 for actuator location FIGURE 9 44 WING FLAP SYS...

Page 307: ...igure 9 43 for actuator stop locations Actuate the flaps to 30 then back to 0 Verify the flap returns to 0 due to the gas spring extension force If the system does not return adjust the 30 actuator st...

Page 308: ...one Aircraft System and Number 06 Flight Controls Consumables None FIGURE 9 46 FLAP ACTUATOR DIAGRAM TASK INSTRUCTIONS 1 Remove main bulkhead panel See Removal and Installation of Inspection Panels an...

Page 309: ...TION 3 Disconnect the flap actuator from its wire harness 4 Disconnect the flap actuator from the flap bellcrank by removing the AN4C10A bolt that fastens them together Retain hardware for reinstallat...

Page 310: ...in hardware for reinstallation 6 Remove flap actuator VERIFICATION METHOD This task is considered complete when the flap actuator has been removed RELATED INFORMATION Inspect Flap Rigging on page 9 65...

Page 311: ...ap actuator in the correct orientation with the spherical bearing lug between the bracket walls NOTE See Figure 9 48for installation reference 2 Connect flap actuator rod end to the flap bellcrank usi...

Page 312: ...None Aircraft System and Number 06 Flight Controls Consumables None TASK INSTRUCTIONS 1 Fold the appropriate wing if desired for easier access 2 Remove the wing fold access panel located on the botto...

Page 313: ...tions to install the gas strut on the flap system TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required...

Page 314: ...to the locked position 6 Deflect the flap surface by hand while watching the gas strut and flap pushrod move Verify that there is no binding or interface 7 Check for proper flap operation See Inspect...

Page 315: ...l move the rudder accordingly 9 10 2 Yaw Controls Diagram Schematic FIGURE 9 50 YAW CONTROLS OVERVIEW FWD Yaw Turnbuckles FWD Yaw Bellcrank Rig Pin Location AFT Yaw Bellcrank Rig Pin Location Rudder P...

Page 316: ...ired None Aircraft System and Number 06 Flight Controls Consumables None TASK INSTRUCTIONS 1 Remove AFT Bulkhead Baggage Panel See Baggage Sidewall Panel Removal on page 3 43 Retain all fastening hard...

Page 317: ...the AFT Bulkhead Baggage Access Window use a tensiometer cable thickness 1 8 in to measure rudder cable tension Refer to Figure 9 52 Ensure they all are within 18 22 lbf of tension Refer to the manuf...

Page 318: ...ned hardware during removal See Center Console Bucket Installation on page 8 8 8 Install the Water Rudder Access Panel using retained hardware during removal See Removal and Installation of Inspection...

Page 319: ...n of Inspection Panels and Fairings on page 3 34 Center Console Bucket Removal on page 8 5 Center Console Bucket Installation on page 8 8 9 10 3 2 Inspect Rudder Pedal Rigging Use task to inspect the...

Page 320: ...oard Removal on page 3 46 2 With the rudder pedals locked in the middle position check angle between rudder rails and rudder pedal arm weldments using a protractor or inclinometer VERIFICATION METHOD...

Page 321: ...ed No Special Tools Required ICA013055 Rudder Deflection Template Parts Required None Aircraft System and Number 06 Flight Controls Consumables None TASK INSTRUCTIONS 1 Position the rudder rigging tem...

Page 322: ...the rudder maximum travel limits Have a helper push each rudder pedal against the stop stop contacts at water rudder bellcrank should be heard While holding very light 1 2 lbf pressure towards neutral...

Page 323: ...ts RELATED INFORMATION Condition and 100 Hour Inspection Aft Fuselage and Empennage on page 3 19 Re Rigging Rudder Pedals on page 9 103 Adjust Yaw Rigging on page 9 100 9 10 4 Maintenance Instructions...

Page 324: ...A007023 BELLCRANK WELDMENT RUDDER 1 ICA007292 BELLCRANK INTERCONNECT RUDDER PEDAL 2 ICA007938 BEARING BLOCK TORQUE TUBE RUDDER 1 ICA007939 PIN BEARING TORQUE TUBE RUDDER 1 ICA009269 BUSHING FLANGED 25...

Page 325: ...MALE 10 32 SLOTTED 2 MS21251 A3S TURNBUCKLE BODY CLIP LKG AL 093X 190 32X2 25 2 MS21251 B5L TURNBUCKLE BODY CLIP LKG BRASS 156X 250 28X4 00 2 MS21256 1 CLIP LKG TRNBKL 1 078 4 MS21256 2 CLIP LKG TRNBK...

Page 326: ...41 Retain all fastening hardware 6 Remove Seatbelt Reel Cover left hand and right hand baggage sidewalls and baggage head liner See Seat Belt Inertia Reel Removal on page 3 39 See Baggage Sidewall Pa...

Page 327: ...tall two 375 in diameter rig pins through the keel in the Yaw Torque Tube Rig Pin holes NOTE Ensure rig pin extends the entire width of the keel through both holes in the keel FIGURE 9 56 FWD YAW BELL...

Page 328: ...th AFT Yaw Control Cables cable thickness 1 8 in Refer to the tensiometer manufacturers calibration card to correctly read cable tension for the cable diam eter measured To achieve the following refer...

Page 329: ...ring onto the LH side of the keel using LOCTITE 243 and the noted hardware Torque hardware to 10 13 in lbs See Figure 9 59 Locate Tensiometer Here Set tension to 18 22 lbs Clip RH SHOWN LH OPPOSITE Cl...

Page 330: ...urnbuckle clips 2 per turnbuckle in place refer to Figure 9 60 a 4 total on aft section of Yaw System 2X ICA012239 Rod End 2X MS21256 2 Wire Terminal b 4 total on mid section of Yaw System 4X MS21256...

Page 331: ...0 TURNBUCKLE LOCATION 16 Position the rudder rigging template ICA013055 or a protractor as shown in Figure 9 61 Center the 0 indication of the rigging template or protractor with respect to the center...

Page 332: ...MENT PLANE 17 Adjust rudder push tube length to set the neutral position of the rudder to be 1 1 trailing edge right This must be done by removing the AN3C7A bolt that secures the FWD side of the push...

Page 333: ...FLIGHT CONTROLS YAW CONTROLS 9 97 CHANGE C3 ICON A5 MAINTENANCE MANUAL CHAPTER 9 FIGURE 9 62 RUDDER PUSH TUBE ADJUSTMENT 18 Repeat step 17 for the LH pedal Bolt Water Rudder Bellcrank Push Rod...

Page 334: ...hin the limits specified Adjust if necessary Torque push tube jam nuts to 40 in lbs Torque through bolts that secure the push tube to 26 in lbs 22 With the aid of another person check the rudder maxim...

Page 335: ...loor Board Installation on page 3 47 28 Install Seat Back and Seat Pan See Seat Back Installation on page 3 51 See Seat Pan Instal lation on page 3 53 29 Install Baggage Floor Boards See Baggage Floor...

Page 336: ...eadliner Removal on page 3 37 Headliner Installation on page 3 38 Inspect Roll Rigging on page 9 17 Removal and Installation of Inspection Panels and Fairings on page 3 34 Cockpit Panels Removal and I...

Page 337: ...and deflection limits must fall within the range specified in the maintenance manual See Inspect Yaw Rigging on page 9 85 7 Reassemble AFT tail access panel See Removal and Installation of Inspection...

Page 338: ...e between the rudder arms and rudder rails to 90 1 2 Remove MS21256 2 turnbuckle clip Tension the rudder pedal cables to control the angle of rudder pedal arms using the rudder cable turnbuckles Re in...

Page 339: ...ng Rudder Pedals Use this task to re rig the rudder pedal rigging TASK INFORMATION Type of Maintenance Heavy Level of Certification LSA RM Task Specific Training Required No Special Tools Required Pro...

Page 340: ...TE Do not swage sleeve in this step 3 Temporarily install the cable to the forward rudder rail mount Install cable to the rudder pedal turnbuckles set turnbuckles to the mid position of adjustment 4 R...

Page 341: ...the rudder inspection procedure See Inspect Yaw Rigging on page 9 85 See Check Water Rudder Rigging on page 11 12 Confirm that at the pedal movement maximum travel the primary stops in the horizontal...

Page 342: ...9 106 FLIGHT CONTROLS YAW CONTROLS ICON A5 MAINTENANCE MANUAL CHANGE C3 CHAPTER 9...

Page 343: ...uel Bladder MY17 Only 10 11 Install Fuel Bladder MY17 Only 10 12 Fuel Tank MY18 10 15 Maintenance Instructions 10 15 Remove Fuel Tank MY18 10 15 Install Fuel Tank MY18 10 19 Coarse Fuel Filter 10 25 C...

Page 344: ...units and components which store and deliver fuel to the engine Includes fuel pump and any associated emergency cutoff device fuel tank shutoff valve filler hose line and cap fuel distribution tubes a...

Page 345: ...IONS 1 While looking at fuel gauge turn master switch on pause for a moment then off The red LED in the fuel level gauge should illuminate momentarily after the switch is turned off Several cycles may...

Page 346: ...e Pin 1 and Sensor Pin 1 Gauge Pin 2 and Sensor Pin 9 Gauge Pin 3 and Sensor Pin 3 5 Reconnect gauge and low level switch connectors 6 Reinstall right seat back closeout and right baggage floor VERIFI...

Page 347: ...OH requirement see Fuel Limitation in POH Winter blend fuel or bad old fuel can cause vapor lock when flying in a lower altitude warmer area Fuel leak Check for leaks See the Maintenance Manual Line 9...

Page 348: ...EL PRESS lights up after the fine fuel filter has been replaced but goes away with power or after engine warms up If problem persists check and replace fuel pressure regulator as necessary See the Mai...

Page 349: ...uel cap from aircraft 2 Connect flexible rubber tube of Fuel Sumping Tool to adapter located inside fuel cap fitting The adapter is inside the fuel cap fitting on the left side 3 Pull back on the plun...

Page 350: ...ength of 6 AN fuel hose with a 6 male AN flare fitting at one end Parts Required None Aircraft System and Number 07 Fuel System Consumables None CAUTION Do not perform any work on the aircraft fuel sy...

Page 351: ...n boost fuel pump 6 Leave the pump running until the desired amount of fuel is removed then turn off ignition and master switches CAUTION Do not leave the fuel pump running unattended Do not allow the...

Page 352: ...be connects the filler cap to the fuel tank TASK INFORMATION Type of Maintenance Line Level of Certification Owner Pilot Task Specific Training Required No Special Tools Required None Parts Required N...

Page 353: ...ump all fuel from bladder See Pump Usable Fuel From Fuel Tank on page 10 8 2 Remove the seat backs See Seat Back Removal on page 3 50 3 Remove the baggage sidewall panels See Baggage Sidewall Panel Re...

Page 354: ...move the filler hose 12 Disconnect the vent hose from the bladder by removing the hose clamp at the tank interface 13 With a 5 8 wrench remove the low level optical switch so as to avoid conflict with...

Page 355: ...hread the sumping hose through the filler hose then attach the sumping hose to the barb on the back of the filler neck Secure the hose with a new 344 15300010 Oetiker clamp and tighten with Ear clamp...

Page 356: ...5 15 Install the seat backs See Seat Back Installation on page 3 51 VERIFICATION METHOD The procedure is complete when the fuel bladder is installed with no leaks RELATED INFORMATION Baggage Sidewall...

Page 357: ...Special Tools Required None Parts Required None Aircraft System and Number 07 Fuel System Consumables None TASK INSTRUCTIONS 1 Remove headliner See Headliner Removal on page 3 37 2 Remove baggage flo...

Page 358: ...HARNESS NOT SHOWN 7 Disconnect the fuel level sensor connector from D9038P See Figure 10 2 8 Use a 7 16 wrench to remove bolt washer and T9028 terminal on fuel level sensor plate See Figure 10 2 9 Rem...

Page 359: ...6 wrench See Figure 10 3 14 Disconnect fuel cell vent hose from barb in fuel cap adapter by removing the mini worm drive clamp 15 Remove worm drive clams from both ends of the fuel filler neck See Fig...

Page 360: ...RAP INSTALLATION 19 Remove two bolts and washers securing the fuel tank straps to the aft end of fuel tank See Figure 10 4 Detail D 20 Remove both fuel tank straps 21 Lift fuel tank subassembly out of...

Page 361: ...uel Tank on page 10 8 10 5 1 2 Install Fuel Tank MY18 Use the following procedure to install the fuel tank TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Trainin...

Page 362: ...TEM FUEL TANK MY18 ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 10 FIGURE 10 5 FUEL TANK INSTALLATION TASK INSTRUCTIONS 1 Ensure isolation strips are properly aligned on fuel tank support structure Se...

Page 363: ...e bolts to 26 in lb 4 Loosely secure the forward ends of the fuel tank straps to the fuel tank brackets using LUBRI CANT and hardware See Figure 10 6 Detail A 5 Adjust isolation channels on the fuel t...

Page 364: ...SUMP LINE AND ELECTRICAL CONNECTIONS 7 Install the bottom end of the filler neck onto the fuel tank opening flange so that there is a 2 1 gap between the bottom face of the filler neck and the top fac...

Page 365: ...e to the elbow fuel return port in the tank and torque to 110 130 in lb with a 11 16 wrench See Figure 10 8 12 Connect fuel line from fuel pump to coarse fuel filter Torque fittings to 110 130 in lb w...

Page 366: ...E NYLON 6 6 30LB 19 Fill the tank with fuel and check for leaks 20 Run the engine and check for line leaks 21 Install the seat backs See Seat Back Installation on page 3 51 22 Install the baggage side...

Page 367: ...and does not need to be replaced unless it is damaged NOTE The orientation of the fuel filter is critical to the fuel system See Coarse Fuel Filter Diagram Schematic on page 10 25 10 6 2 Coarse Fuel...

Page 368: ...WIRE SAFETY CRES 032 TASK INSTRUCTIONS 1 Remove baggage floor See Baggage Floor Removal on page 3 41 NOTE Seat backs may be removed for easier access See Seat Back Removal on page 3 50 2 Close the fu...

Page 369: ...WIRE NOTE If the filter is damaged replace it with CLEANABLE 62MICRON FUEL FILTER FX375 M 9 Place the fuel filter approximately midway inside the loop type clamp 10 Confirm that when installing the fi...

Page 370: ...ning Required No Special Tools Required None Parts Required FX375 M FILTER FUEL CLEANABLE 62MICRON Aircraft System and Number 07 Fuel System Consumables LOCTITE 243 THREADLOCKER PRIMERLESS OIL TOL REM...

Page 371: ...ing the filter the arrow direction is the same as before and the correct in and out fittings are tightened in the appropriate inlet and outlet fittings 11 Wipe away or clean any fuel which may have dr...

Page 372: ...Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 07 Fuel System Consumables None TASK INSTRUCTIONS 1 Remove headliner...

Page 373: ...fuel filter inlet loosen the 6 AN B nut with an 1116 wrench while holding the 14mm adapter fitting with a 3 4 wrench 8 Remove the fuel filter and attached plumbing and place on a clean work surface 9...

Page 374: ...NCE MANUAL CHANGE C2 CHAPTER 10 FIGURE 10 13 FINE FUEL FILTER AND ATTACHED PLUMBING 11 Use two 3 4 wrenches to remove the inlet adapter fitting from the old filter Discard the 14mm washer See Figure 1...

Page 375: ...l filter has been removed RELATED INFORMATION Install Fine Fuel Filter on page 10 33 Headliner Removal on page 3 37 10 7 1 2 Install Fine Fuel Filter Use the following instruction to install the fine...

Page 376: ...end of the filter bypass tube and the carbon wing spar This slightly tipped back positioning ensures clearance to the headliner Snug the connecting 6 AN B nuts finger tight 6 Install the B clamp aroun...

Page 377: ...ystem and Number 07 Fuel System Consumables None TASK INSTRUCTIONS 1 Locate the connection between the fuel cap fitting and routed through the fuselage to the left wing 2 Remove the fuel cap 3 Place a...

Page 378: ...10 36 FUEL SYSTEM FUEL TANK VENT LINE ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 10 RELATED INFORMATION Condition and 100 Hour Inspection Fuel Systems on page 3 13...

Page 379: ...3 Canopy Installation 11 4 Seawings 11 7 Maintenance Instructions 11 7 Seawings Platform Tip Removal and Installation 11 7 Repair of Seawings Tip Attach Pins and Bushings 11 8 Water Rudder 11 11 Inspe...

Page 380: ...el ballast provision water rudder and water rudder guard Seawings center wing section IPS riser attachment s engine cowl and vertical tail including the air rudder and its hinges and counterbal ance I...

Page 381: ...Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 08 Fuselage and Vertical Tail Cons...

Page 382: ...y has been removed RELATED INFORMATION Left Instrument Panel Top Panel Removal on page 8 19 Right Instrument Panel Top Panel Removal on page 8 17 Left Instrument Panel Top Panel Installation on page 8...

Page 383: ...811 canopy hinge weldment to the canopy frame Coat the bolts with Tef Gel prior to installation 5 Tighten the bolts just enough that the canopy can be moved on the frame with some effort 6 Have a help...

Page 384: ...5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 11 RELATED INFORMATION Left Instrument Panel Top Panel Removal on page 8 19 Right Instrument Panel Top Panel Removal on page 8 17 Left Instrument Panel Top Panel...

Page 385: ...ings Tip Aircraft System and Number 08 Fuselage and Vertical Tail Consumables None TASK INSTRUCTIONS 1 Use a 3 8 wrench to remove the single AN3 C5A attachment bolt and two NAS1149C0363R washers from...

Page 386: ...ATION Description on page 20 2 Repair of Seawings Tip Attach Pins and Bushings on page 11 8 11 3 1 2 Repair of Seawings Tip Attach Pins and Bushings Use the following procedure to repair the Seawings...

Page 387: ...Use Plexus MA830 adhesive b Prepare all bond surfaces pin and carbon structure by first cleaning with cloth and isopropyl alcohol then abrading with 120 180 grit aluminum oxide emery paper Shiny bond...

Page 388: ...CAL TAIL SEAWINGS ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 11 VERIFICATION METHOD Procedure is complete when Seawings tip has been attached RELATED INFORMATION Seawings Platform Tip Removal and In...

Page 389: ...and Installation of Inspection Panels and Fairings on page 3 34 2 Using a flashlight and inspection mirror as required inspect attachment and integrity of the water actuator return spring cables turn...

Page 390: ...rub on the hull 6 Verify that when extended the water rudder surface can be deflected aft by hand the deflection being allowed but resisted by the return spring 7 Re install the aft baggage panel and...

Page 391: ...e stop stop contact at water rudder bellcrank should be heard While holding very light 1 2 lbf pressure towards neutral on the water rudder trailing edge to remove play record maximum left water rudde...

Page 392: ...4 22 Swage Fitting AN100C 3 Thimble Aircraft System and Number 08 Fuselage and Vertical Tail Consumables LOCTITE 603 LOCTITE 243 TASK INSTRUCTIONS 1 Install bushing M81934 2 05C012 into water rudder u...

Page 393: ...N003 and thimbles AN100C 3 FN 004 through existing eye bolts FN 006 VERIFICATION METHOD Verify that the water rudder rotates horizontally 40 5 in both directions when the corresponding full rudder inp...

Page 394: ...screws that hold the bottom water rudder hinge tang to the hull 9 Pull the water rudder assembly down and out of the hull Doing so will also pull the actuation cables so be careful and guide the cable...

Page 395: ...855A510 Retaining Pin MS24694C53 Screws 97851A104 Binding Post 91950A029 Washer AN100C 3 Cable Thimble Aircraft System and Number 08 Fuselage and Vertical Tail Consumables Tef Gel LOCTITE 609 LOCTITE...

Page 396: ...dder bellcrank visible from the bottom The rudder right side cable must pass to the right of the bushing and the left cable to the left of it 14 Pull cable ends out through the water rudder access pan...

Page 397: ...t twisted and that the retraction end will connect to the water rudder actuator and the extension end to the extension spring 20 Attach the retraction turnbuckle assembly by inserting the clevis pin t...

Page 398: ...11 20 FUSELAGE AND VERTICAL TAIL WATER RUDDER ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 11...

Page 399: ...allation 12 6 Remove Horizontal Tail Tip Lock Switches 12 6 Air Rudder Removal 12 9 Elevator Pushrod Removal 12 10 Horizontal Tail Removal 12 11 Horizontal Tail Installation 12 13 Elevator Pushrod Ins...

Page 400: ...ONTAL TAIL DESCRIPTION ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 12 12 1 Horizontal Tail Description Horizontal tail includes the structure of the elevator control surface Includes skins ribs webs...

Page 401: ...ntal tail tips 2 Check horizontal tail for play in forward aft direction by applying load to the outboard side of horizontal tail forward and aft The joint between the vertical tail and the horizontal...

Page 402: ...kin Use the following to inspect the Horizontal Tail Empennage skin for damage delaminations TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No...

Page 403: ...ines for the main and aft HT spar See Manual Tap Test on page 3 55 2 Conduct a tap test on all horizontal tail skins over bond lines for center and tip ribs 3 Remove horizontal tail tip access panels...

Page 404: ...tail 12 3 1 1 Remove Horizontal Tail Tip Lock Switches Use the following procedure to remove the two horizontal tail tip lock switches TASK INFORMATION Type of Maintenance Line Level of Certification...

Page 405: ...INTENANCE 12 7 CHANGE C1 ICON A5 MAINTENANCE MANUAL CHAPTER 12 FIGURE 12 2 REMOVE HORIZONTAL TAIL TIP ACCESS PANEL LH SHOWN RH OPPOSITE 2 Remove the 4 screws washers and nuts securing limit switches S...

Page 406: ...ONTAL TAIL HORIZONTAL TAIL GENERAL MAINTENANCE ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 12 FIGURE 12 3 REMOVE SCREWS SECURING SWITCHES 3 Unplug and remove limit switches from wiring harness See Fi...

Page 407: ...wo limit switches are completely removed from horizontal tail this task is complete RELATED INFORMATION Horizontal Tail Removal on page 12 11 Removal and Installation of Inspection Panels and Fairings...

Page 408: ...y removing the AN3C10A bolt 3 Deflect rudder to the left and working through the cutout in the skin at the root of the rudder remove the AN3C6A bolt and NAS1149C0332R washer attaching the rudder root...

Page 409: ...R washers that attach the aft end of the pitch pushrod to the elevator horn 3 Working through the aft small circular hole in the top right side of VT tip remove the AN3C7A bolt and NAS1149C0332R washe...

Page 410: ...wire from the heads of the aft vertical tail horizontal tail attach bolts 4 At the forward vertical tail horizontal tail attach accessed through the forward access hole on the right side of the verti...

Page 411: ...aft System and Number 09 Horizontal Tail Consumables None For the steps involved in removing the horizontal tail See Horizontal Tail Removal on page 12 11 TASK INSTRUCTIONS 1 Verify that the final pit...

Page 412: ...f the aft attach bolts together using MS20995C32 safety wire reference AC 43 13 1B 10 Install an ME000640 plug into the forward access hole on the right side of the VT tip VERIFICATION METHOD The task...

Page 413: ...he pitch pushrod so that it inserts into the elevator horn with holes aligned 5 Install an AN3C11A bolt with one NAS1149C0332R washer under its head through the elevator horn attaching it to the pushr...

Page 414: ...1149C0332R washer and AN3C6A bolt attaching rudder root fitting to drive fitting in fuselage 4 Connect rudder pushrod to rudder with an NAS1149C0363R washer and AN3C10A bolt 5 Install air rudder acces...

Page 415: ...ches D9013P to D9013J D9014P to D9014J b RH switches D9015P to D9015J D9016P to D9016J 2 Install switches See Figure 12 3 Torque LIMIT SWITCH screws to 8 in lbs Torque TAIL TIP LOCK LIMIT SWITCH screw...

Page 416: ...s VERIFICATION METHOD Once the two limit switches are installed and functional this task is complete RELATED INFORMATION Horizontal Tail Removal on page 12 11 Removal and Installation of Inspection Pa...

Page 417: ...remove it from the detent position and rotate the latch approximately 180 2 Grasp the tip and slide it away from main horizontal tail until the cylindrical spar clears the struc ture 3 Support the hor...

Page 418: ...System and Number 09 Horizontal Tail Consumables LOCTITE 220 TASK INSTRUCTIONS 1 Pull downward on the tip lock latch to remove it from the detent position and rotate the latch approximately 180 2 Gras...

Page 419: ...remove it clean the threads and reinstall 6 Apply LOCITITE 220 to the base of the new pin after torquing This is a wicking type of LOCI TITE and it will be drawn into the threads Wipe off any excess...

Page 420: ...12 22 HORIZONTAL TAIL HORIZONTAL TAIL TIP PIN ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 12...

Page 421: ...Multiple Systems Controller MSC Replacement 13 27 Remove Instrument Cluster 13 29 Install Instrument Cluster 13 31 Access Center Stack Instruments and Switches 13 32 Remove and Install Hour Meter 13 3...

Page 422: ...omm Antenna Installation 13 63 DAC Memory Unit 13 65 Maintenance Instructions 13 65 DAC Memory Unit Removal 13 65 DAC Memory Unit Re Installation 13 66 DAC Software Version 13 67 Verify DAC Software V...

Page 423: ...equipment controls headset jacks intercom switches and auxiliary microphone input jack The Angle of Attack indicating includes the sensor and pitot static ports and associated hose tubing if pneumatic...

Page 424: ...ion in this section should be used to verify that markings shown in solid lines are legible TASK INFORMATION Type of Maintenance Line Level of Certification Owner Pilot Task Specific Training Required...

Page 425: ...INSTRUMENTS AND AVIONICS TROUBLESHOOTING 13 5 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 13 2 Left Crossbeam...

Page 426: ...13 6 INSTRUMENTS AND AVIONICS TROUBLESHOOTING ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 13 3 Overhead Console 4 Parking Brake...

Page 427: ...INSTRUMENTS AND AVIONICS TROUBLESHOOTING 13 7 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 13 5 Center Armrest Bucket VERIFICATION METHOD Verify all lines and text are visible and legible...

Page 428: ...ft System and Number 10 Instruments and Avionics Consumables None The magnetic direction indicator is part of the attitude indicator AI which is located in the center of the flight instrument cluster...

Page 429: ...ation 6 The instrument is now calibrated for the magnetic field of the aircraft When INSTR 1 fuse is pulled all gauges on the instrument panel will be INOP 7 Compare magnetic direction indicator headi...

Page 430: ...can be a sign of vapor lock Fuel leak Fuel Pressure Regulator failure Weak Failed Fuel pump Low fuel level High fuel pressure 46 5 FP 50 0 Fuel fine filter clogged Blockage between regulator and fuel...

Page 431: ...Electrical System Wiring Diagrams on page 6 4 Alternator B failure Replace alternator See Rotax 912 iS Sport 912 iS 2 Heavy Maintenance Manual alternator replacement ALTERNATOR Flashing DAC software...

Page 432: ...ttery not charging with engine running Diagnose issue using wiring schematics See Electrical System Wiring Diagrams on page 6 4 Alternator B failure Replace alternator See Rotax 9912 iS Sport 912 iS 2...

Page 433: ...k wiring T9913 to 30 amp circuit breaker Check for continuity between D9069P and D9069J at Fuse Box X3 connector pin 3 Inspect wiring through SM9062 Check wiring from T9110 30 amp circuit breaker to O...

Page 434: ...winglock switch if necessary See Wing Lock on page 17 24 LH or RH horizontal tail tip not secured Secure LH RH HT tip See Horizontal Tail on page 12 1 LH or RH horizontal tail tip lock switch malfunct...

Page 435: ...intenance 13 3 1 Overhead Console Component Replacement Use this procedure to replace any indicated component mounted in the overhead console TASK INFORMATION Type of Maintenance Line Level of Certifi...

Page 436: ...R 13 None TASK INFORMATION Find Number Part Number Name 003 SJTC02000 Terminal Block Mounting Track 004 W23 X1A1G 30 Circuit Breaker 30A 005 ICA006179 Horn Stall Warning 006 E 04 5 Switch Remote ELT T...

Page 437: ...e and replace any damaged or faulty compo nent indicated in the figure and table below 6 Use the graphic and associated parts list table to select the appropriate replacement compo nents and then remo...

Page 438: ...mponent RELATED INFORMATION ELT Audio Alert Indicator Battery Replacement on page 13 52 ELT Remote Control Panel Battery Replacement on page 13 50 Remove Dome Light Switch on page 6 64 Install Dome Li...

Page 439: ...light up when the master switch is ON Alterna tively visually check that the fuse is blown by removing it from the fuse panel 2 Pull down on the fuse to remove it from the overhead fuse panel 3 Select...

Page 440: ...13 20 INSTRUMENTS AND AVIONICS INSTRUMENTS AND AVIONICS GENERAL MAINTENANCE ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 13 FIGURE 13 2 FUSE PANEL...

Page 441: ...System Wiring Diagram Engine Interface on page 6 8 12V USB Outlets 12V outlet System Wiring Diagram Outlets on page 6 26 USB outlet System Wiring Diagram Outlets on page 6 26 INT LIGHTS Interior Light...

Page 442: ...on page 13 8 System Wiring Diagram Mode C on page 6 25 TRIM Pitch Trim Actuator Pitch Trim Actuator on page 9 53 System Wiring Diagram Control Sticks Pitch Trim on page 6 6 MAIN GEAR Main Landing Gea...

Page 443: ...Fuel low sensor Fuel Low Level Light Diagnostic on page 10 3 System Wiring Diagram Fuel on page 6 15 Bilge sensor System Wiring Diagram Bilge on page 6 5 Water rudder LED System Wiring Diagram Water R...

Page 444: ...am Flaps on page 6 14 NOSE GEAR Nose Landing Gear Actuator System Wiring Diagram Landing Gear on page 6 22 ENG GEAR Relays LANE A relay System Wiring Diagram Engine Interface on page 6 8 LANE B relay...

Page 445: ...alibration of the AOA pres sure transducer TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Ai...

Page 446: ...or RELATED INFORMATION Condition and 100 Hour Inspection Avionics and Electrical on page 3 23 13 3 4 Replace Instrument Panel Gauge Use the following to replace any of the nine gauges in the flight in...

Page 447: ...Replace gauge and install four attachment screws Apply a small amount of LOCTITE 222 Torque to 6 10 in lb 4 Re install instrument cluster into the aircraft See Install Instrument Cluster on page 13 3...

Page 448: ...tions going to the MSC Disconnect the four nylon tubes where they insert into the push on connectors at the MSC Label where they go and seal all open ends to prevent debris from entering the tubes and...

Page 449: ...ument gauges or annunciator panel TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft Sy...

Page 450: ...ATTACHMENT DETAIL EXPLODED VIEW 3 Disconnect all electrical connections to the instrument cluster Take note of wiring harness layout for re installation 4 Disconnect two static and one pitot tube fro...

Page 451: ...moved from the instrument cluster RELATED INFORMATION Pitot Static Angle of Attack AOA System on page 13 70 Install Instrument Cluster on page 13 31 Replace Instrument Panel Gauge on page 13 26 Replac...

Page 452: ...e instrument cluster to aircraft crossbeam rib with four 8 32 attachment screws Apply small amount of LOCTITE 222 See Figure 13 3 4 Attach static tube to the altimeter 5 Attach static and pitot tubes...

Page 453: ...AINTENANCE 13 33 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 13 LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 10 Instrument and...

Page 454: ...ucket Table 13 1 Center Stack Wire Instruments Wiring Instrument Switch Connection From Connection To Trim Indicator D9046J D9046P Flap Switch D9061J D9061P Landing Gear Switch D9094J D9094P Heat Cont...

Page 455: ...13 FIGURE 13 6 CENTER STACK WIRE HARNESS 2 Access the instruments and switches listed in the following table See Center Console Bucket Removal on page 8 5 The following table details the connections f...

Page 456: ...Remove and Install Hour Meter This section contains instructions to remove and install hour meter TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Require...

Page 457: ...TASK INSTRUCTIONS 1 Remove center console bucket See Center Console Bucket Removal on page 8 5 2 Access the hour meter See Throttle Handle and Bezel Removal on page 8 10 See Throttle Handle and Bezel...

Page 458: ...which illu minate in amber to draw pilot attention to aircraft system status or failures that may warrant action The four caution lights are BATTERY FUEL PRESS ENGINE and ALTERNATOR For detailed meani...

Page 459: ...METHOD If all lights are lit the test has been successfully completed RELATED INFORMATION Condition and 100 Hour Inspection Operational Inspection on page 3 25 Replace Annunciator Panel on page 13 39...

Page 460: ...PANEL ANNUNCIATOR and re install four attachment screws Torque screws to 2 4 in lb Check that hardware is secure CAUTION PANEL ANNUNCIATOR is an electrostatic sensitive device Do not open or handle e...

Page 461: ...is located at the top of the engine cowl See Figure 13 8 The transmitter and battery are located beneath the center console panel forward of the throttle handle See Figure 13 9 The audio alert and swi...

Page 462: ...n Instructions 13 5 3 1 ELT Access The following contains instructions for accessing the ELT for inspection and maintenance TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task...

Page 463: ...r The access panel is located at the bottom of the forward side of the center console near the kneed pads 2 Swing the top edge of the access panel forward then remove it by pulling it up disengaging t...

Page 464: ...ote Control Panel Battery Replacement on page 13 50 ELT Battery Self Test on page 13 47 ELT Battery Replacement on page 13 48 ELT Audio Alert Indicator Battery Replacement on page 13 52 13 5 3 2 ELT I...

Page 465: ...rrow graphic of ELT unit is on top and points forward 4 Use a screwdriver or similar tool approximately 10 inches long to open the latches of the quick release strap 5 Disconnect cables NOTE Although...

Page 466: ...attach the battery case to the ELT transmitter assembly according to Section 11 of ACK Tech nologies Inc Model E 04 ELT Installation Operation Manual 12 Verify the fasteners of the quick release strap...

Page 467: ...nitiated 1 When the ELT is in the Armed position pressing the Reset Test switch on the cockpit remote control RCPI initiates a self test 2 When the main switch of the ELT is moved from the Off positio...

Page 468: ...beeps alert you that there is a trouble condition The two second delay is to allow you to be ready to count the second set of beeps Trouble code sequence 2 5 beeps two second delay 2 5 beeps Trouble C...

Page 469: ...n the OFF position install the new sealed battery pack P N E 04 0 The battery pack is designed so the battery can only be installed in the proper orientation a Wet the O ring with a mild dish soap sol...

Page 470: ...kaline batteries such as Eveready A 544 or equivalent may also be used Under normal operating conditions the lithium battery must be replaced every 10 years The alka line batteries must be replaced ev...

Page 471: ...the contacts need cleaning use only non abrasive electrical contact cleaner and a stiff brush Abrasive cleaners will remove the nickel and gold plating from contacts 7 Insert the battery with the pola...

Page 472: ...icator Battery Replacement on page 13 52 Overhead Console Component Replacement on page 13 15 13 5 4 3 ELT Audio Alert Indicator Battery Replacement The following instructions detail how to replace th...

Page 473: ...cure the top cover to the audio alert indicator P N E 04 7 5 Carefully remove the top of the indicator exposing the battery compartment 6 Install a Duracell CR 2 3 or equivalent battery Make sure to o...

Page 474: ...replaced and the new battery expi ration date has been recorded in the log book NOTE The ELT Remote Battery should be checked and replaced at the same time RELATED INFORMATION ELT Access on page 13 42...

Page 475: ...f Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required ICA012199 ELT ANTENNA ICA012182 ICA009540 ELT ANTENNA GROUND Aircraft Sys...

Page 476: ...GURE 13 11 REMOVE TRANSPONDER ANTENNA 3 Remove the nut and star washer to remove the ELT ANTENNA 4 If ground wires need to be replaced carefully remove the adhesive bonding the eight ground wires to t...

Page 477: ...f no ground wires are in place a Install ground wires 4 terminals on lower unpainted side of cowl and secure using star washer and nut Ensure that each ring terminal is at a 90 angle from one another...

Page 478: ...is oriented as shown in Figure 13 15 Secure the noted stud using lock washer and nut both included with antenna 11 If no ground wires already in place a Install ground 4 terminals on the noted stud o...

Page 479: ...AVIONICS ELT 13 59 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 13 FIGURE 13 15 INSTALL TRANSPONDER ANTENNA 13 Ensure ELT and transponder antenna ground wires do not overlap and are not touching one a...

Page 480: ...13 60 INSTRUMENTS AND AVIONICS ELT ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 13 FIGURE 13 16 BOTTOM VIEW OF TOP ENGINE COWLING AFTER ANTENNAS ARE INSTALLED BOTTOM VIEW...

Page 481: ...become tacky before removing masking tape Use caution to ensure wires do not get pulled out of the adhesive Allow 30 minutes for the adhesive to cure 15 Reinstall the top engine cowling See Install En...

Page 482: ...he aircraft See Figure 13 18 The antenna transmits on the VHF radio spec trum also known as aircraft band This allows for communication between air traffic control and aircraft pilot 13 6 2 VHF Comm A...

Page 483: ...SK INSTRUCTIONS 1 Remove antenna 4 8 32x1 00 screws 2 Raise the antenna from the horizontal tail surface to disconnect the BNC connector VERIFICATION METHOD This task is complete when the comm antenna...

Page 484: ...raft System and Number 10 Instruments and Avionics Consumables None The comm antenna is located on top of the horizontal tail TASK INSTRUCTIONS 1 Connect the antenna to the BNC connector 2 Install ant...

Page 485: ...Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required 2mm long reach hex head wrench Parts Required None Aircraft System and Number 10 Instruments a...

Page 486: ...been removed RELATED INFORMATION DAC Memory Unit Re Installation on page 13 66 13 7 1 2 DAC Memory Unit Re Installation The A5 has a memory unit that records data from operations Use this task to re...

Page 487: ...rd plastic pin into the left side instrument panel top receptacle Align the ball studs on the cover with the receptacles on the instrument panel cover and press the ball studs down into the rubber rec...

Page 488: ...he DAC memory unit See DAC Memory Unit Removal on page 13 65 5 Connect DAC memory unit to the memory unit adapter and connect to USB port on a computer 6 Open EMDS on the computer click on the SD card...

Page 489: ...he DAC data file The expanded view shows the file s basic information Verify the EMU SW Version indicates the latest software See Figure 13 20 FIGURE 13 20 VERIFY DAC SOFTWARE VERSION 8 If the softwar...

Page 490: ...ton PS 525 Pitot Static Test Set or equivalent ITW Tacky Tape Parts Required None Aircraft System and Number 10 Instruments and Avionics Consumables None The Preston PS 525 Pitot Static Test Set is us...

Page 491: ...heck or alternative pitot static leak check operation See Alter nate Pitot Static Leak Test Procedure on page 13 81 Record the results in the Verification Method section below 3 Perform the AOA system...

Page 492: ...tic Tester Set Up Instructions for setting up the test equipment for completing the pitot static AOA leak tests TASK INSTRUCTIONS 1 Connect the pitot hose to the Pressure side of the PS 525 unit 2 Con...

Page 493: ...Using ITW Tacky Tape secure the BFST26 820 connector to the surface of the vertical tail ensuring there is no air leak Ensure the center of the connector is clear to allow for air flow 5 Seal the righ...

Page 494: ...CE MANUAL CHANGE C2 CHAPTER 13 6 Drape the static port hose up and over the top of the rudder to remove any strain on the hose that could cause the tacky tape to slowly peel off VERIFICATION METHOD Do...

Page 495: ...to avoid pressures and rapid changes of pressure that could damage the instruments TASK INSTRUCTIONS 1 On the front panel of the PS 525 tester ensure that the Pressure Pump and Vacuum Pump switches a...

Page 496: ...mately 3 4 of a turn counter clock wise before the valve opens Climb the altitude on the display no faster than 4 000 ft min to approximately 1000 ft greater than the indicated number with the Vacuum...

Page 497: ...lay 15 Press Leak Check two more times until the screen indicates 60 sec then press the Units button to start the leak check NOTE The ICON standard is no more than a 5 knot total leak over 60 seconds...

Page 498: ...ng not to exceed 4 000 ft min on the Altitude display 22 Close the Crossbleed valve 23 Carefully open the Pressure Control valve to bring the Pressure Reservoir indicator to 0 psi 24 Carefully open th...

Page 499: ...pplying pressure to the pitot static system to avoid pressures and rapid changes of pressure that could damage the instruments TASK INSTRUCTIONS 1 Prepare the Preston Pressure Pitot Static Tester Mode...

Page 500: ...ions of the day Note the altitude shown as a reference for future steps 9 Switch on the Vacuum Pump until it reads 15 20 inHg on the Vacuum Reservoir indicator 10 Carefully open the Vacuum Control val...

Page 501: ...test 19 Open all valves for storage 20 Turn the PS 525 tester unit power to Display Off 21 Record the results of the AOA system leak check in the Verification Method form of the parent task See Pitot...

Page 502: ...d the new airspeed reading result after one minute 4 Remove test setup 5 Adjust the altimeter baro setting until an even altitude is displayed 6 Seal one instrument static port with tape 7 Secure syri...

Page 503: ...outside of ICON limits then there is a leak in the pitot static system and the full system must be inspected and all leaks repaired RELATED INFORMATION Multiple Systems Controller MSC Replacement on p...

Page 504: ...ater switch OFF Table 13 3 Altimeter Calibration VERIFICATION METHOD Ensure the altimeter reading is within tolerance at current location RELATED INFORMATION Condition and 100 Hour Inspection Avionics...

Page 505: ...equired None Aircraft System and Number 10 Instruments and Avionics Consumables None TASK INSTRUCTIONS 1 Remove the Right Instrument Panel Top Panel See Right Instrument Panel Top Panel Removal on pag...

Page 506: ...are found proceed to Check Wing Connections See Check Wing Connections on page 13 86 13 8 2 2 2 Check Wing Connections Use the following procedure to check the wing connections for leaks TASK INFORMA...

Page 507: ...ectors 4 Mark the tube and check connection at push on tube connectors blow air into wing lines to clear any moisture or sitting water in lines Reconnect the tubes in their original order 5 Perform a...

Page 508: ...13 88 INSTRUMENTS AND AVIONICS PITOT STATIC ANGLE OF ATTACK AOA SYSTEM ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 13...

Page 509: ...stment Procedure 14 19 Brake Line 14 21 Maintenance Instructions 14 21 Brake Line Replacement Procedure 14 21 Rudder Pedal Connector Lines Replacement 14 21 Forward Lines Replacement 14 23 Aft Lines R...

Page 510: ...on 14 62 Nose Landing Gear NLG Cam Follower Replacement 14 66 Nose Landing Gear Steering Bearing Replacement Procedure 14 68 Remove Nose Landing Gear Steering Bearing 14 68 Prepare Nose Gear and Nose...

Page 511: ...The stainless steel wheel bear ings are corrosion resistant and extend time between required maintenance when used in salt water The self centering full 360 castering nose wheel allows for ease of mov...

Page 512: ...14 4 LANDING GEAR DIAGRAM SCHEMATIC ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 14 14 2 Diagram Schematic...

Page 513: ...Tools Required Inclinometer Wing Jack Point Adapter ICA009750 Parts Required None Aircraft System and Number 11 Landing Gear Consumables None TASK INSTRUCTIONS 1 Remove the Aft Bulkhead Baggage Panel...

Page 514: ...g gear indicator is in the landing gear down position VERIFICATION METHOD Check that the results are within the acceptable limits RELATED INFORMATION Removal and Installation of Inspection Panels and...

Page 515: ...Jackpoint Scales on page 3 32 3 Initiate gear retraction 4 Verify landing gear indication moves to In Transit while actuators are working 5 Once stopped verify blue landing gear up indication has bee...

Page 516: ...on Jackpoint Scales on page 3 32 Condition and 100 Hour Inspection Landing Gear on page 3 14 14 3 3 Main Landing Gear Inspection Inspect the main landing gear system TASK INFORMATION Type of Maintena...

Page 517: ...ior of the aircraft again vibrate the control system by rotating the bell crank clockwise and counter clockwise There should not be an excessive amount of play or travel in the system 4 Ensure the mec...

Page 518: ...ur Inspection Landing Gear on page 3 14 Removal and Installation of Inspection Panels and Fairings on page 3 34 Empty Weight and CG Measurement While on Jackpoint Scales on page 3 32 Re Bond Main Land...

Page 519: ...Measure ment While on Jackpoint Scales on page 3 32 3 Move Master Switch to ON position 4 Verify icon 3 see illustration is lit 5 Move Landing Gear Lever to UP position 6 Verify icon 2 see illustrati...

Page 520: ...c Training Required No Special Tools Required Wing Jack Point Adapter ICA009750 Parts Required None Aircraft System and Number 11 Landing Gear Consumables None This task can be readily combined with t...

Page 521: ...n or extension takes significantly longer then additional investigation is required Contact ICON for further instructions RELATED INFORMATION Landing Gear Indicator Lights on page 14 10 14 3 6 Nose Wh...

Page 522: ...illustration 3 Confirm that all attachment hardware is securely in place special attention should be given to the cotter pin used to prevent un threading of the wheel attachment hardware Refer to ill...

Page 523: ...actuator has a fuse blown TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required Wing Jack Point Adapter ICA009750 Parts Req...

Page 524: ...e Replace Overhead Console Fuses on page 13 18 VERIFICATION METHOD Retract and extend the landing gear to verify actuation of the landing gear RELATED INFORMATION Replace Overhead Console Fuses on pag...

Page 525: ...3 32 2 Disconnect the actuator from the bell crank 3 With the end of the actuator free continue to watch the excessive friction occurring within the actuator installation after powering up the aircra...

Page 526: ...ing Gear Consumables See Beringer Maintenance Manual TASK INSTRUCTIONS 1 All regular maintenance tasks on the braking system shall be done in accordance with the proce dures in the Beringer Wheel and...

Page 527: ...pe of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 11 Landing Gear Consumables None TASK...

Page 528: ...ft off the jacks See Right Instrument Panel Top Panel Installation on page 8 18 See Removal and Installation of Inspection Panels and Fairings on page 3 34 VERIFICATION METHOD Power up the aircraft an...

Page 529: ...opriate procedure below to replace a line RELATED INFORMATION Wheel and Brake System Maintenance on page 14 18 General Brake Line Termination Procedure on page 14 29 14 5 1 1 1 Rudder Pedal Connector...

Page 530: ...emove the cable tie holding the center of the brake lines to the structure 2 Disconnect the brake line by using an 11mm wrench to hold the HYD 006P adapter fitting in the brake cylinders and a 1 2 inc...

Page 531: ...freely with no brake line interference VERIFICATION METHOD Bleed the brakes per the procedure in the Beringer Manual Check for correct operation and no leaks RELATED INFORMATION Wheel and Brake System...

Page 532: ...l Brake Line Termi nation Procedure on page 14 29 6 Connect the brake line B nuts to the parking brake valve and lower connection point on the brake master cylinder 7 With the terminated end wrap appr...

Page 533: ...er 11 Landing Gear Consumables F4TAPEBLACK Silicone Tape Smooth On Sil Poxy NOTE The two aft brake lines Left and Right that run between he brake calipers and the parking brake valve are nearly identi...

Page 534: ...ng tape then cut through the tape This will result in a neater cut of the stainless braid making it easier to pass the hose through the MLG leg guides 7 Terminate one end of the hose with a HYD 008P B...

Page 535: ...re the brake line passes through the MLG boot by injecting Sil Poxy into the joint and completely around the line Leave a small fillet of Sil Poxy all around the joint to ensure a good water seal 13 F...

Page 536: ...re Figure 14 11 shows a typical mount FIGURE 14 11 PARKING BRAKE VALVE 15 Trim excess length from the brake line if desired and terminate the parking brake valve end of the line with a HYD 008P B nut...

Page 537: ...TION Wheel and Brake System Maintenance on page 14 18 General Brake Line Termination Procedure on page 14 29 14 5 1 2 General Brake Line Termination Procedure Use the following procedure for preparing...

Page 538: ...ing Gear Consumables Tef Gel TASK INSTRUCTIONS 1 Cut hose to length with a pair of sharp hose or wire cutters 2 Clean any debris from cut end and gently reshape back to circular section with a pair of...

Page 539: ...the stainless steel braid at the end of the hose separating them from the hose s PTFE inner liner for a length of 2 inches minimum see Figure 14 14 6 Push the chamfered end of the olive onto the PTFE...

Page 540: ...ittings use a 1 2 inch wrench to hold the fitting 12 Use an 11mm wrench to torque the socket to 110 in lbf allowing the hose to spin to avoid kinking it VERIFICATION METHOD The procedure is complete w...

Page 541: ...pecial Tools Required None Parts Required None Aircraft System and Number 11 Landing Gear Consumables None TASK INSTRUCTIONS 1 Unless already performed remove any interior panels needed to gain access...

Page 542: ...equired No Special Tools Required None Parts Required None Aircraft System and Number 11 Landing Gear Consumables Tef Gel TASK INSTRUCTIONS 1 Install parking brake handle on the parking valve using th...

Page 543: ...lace parking brake valve in its installation location as shown but do not install bolts FIGURE 14 19 ORIENTATING THE PARKING VALVE 7 Connect AFT brake lines to parking brake valve Torque fittings to 9...

Page 544: ...parking brake 2x at brake master cylinders to 90 132 in lb Check that hardware is secure 10 Install parking brake using Neoprene washers Apply Tef Gel to bolt threads Torque 2x bolts to 13 15 in lb C...

Page 545: ...ow removes both left and right MLG assemblies If only removing one side perform only those steps needed CAUTION Whenever standing sitting or kneeling inside the fuselage with floor panels removed suit...

Page 546: ...rcraft guiding the brake lines through the bulk head 12 Disconnect the MLG actuator from the aircraft electrical harness 13 Use a 3 8 wrench to remove the AN3C27A bolt washer from the top of the MLG b...

Page 547: ...mbly through the opening in the bottom of the right Seawings and into position between the main bulkheads This assembly should be complete with bellcrank actuator pushrod trunnion leg and boot 4 Ensur...

Page 548: ...nect the MLG actuator electrical connector to the aircraft harness 17 Route the left and right brake lines forward to the parking brake valve Reinstall any cable ties that were removed and install the...

Page 549: ...cement TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 11 Landing...

Page 550: ...ASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 11 Landing Gear Con...

Page 551: ...ay be reduced The initial cure time is 15 minutes with full strength achieved in 24 hours at room temperature 73 F 5 Use adhesive tape to secure the boot cuff to the gear leg so that it does not shift...

Page 552: ...FORMATION Re Bond Main Landing Gear MLG Boot on page 14 44 Main Landing Gear MLG Wheel and Axle Installation on page 14 48 Main Landing Gear MLG Removal on page 14 37 Main Landing Gear MLG Installatio...

Page 553: ...erial should be removed 5 Clean the bonding area surfaces of boot and substrate with isopropyl alcohol and a clean cloth A cotton swab or similar tool may be useful for getting into the edges 6 Prop t...

Page 554: ...None Parts Required None Aircraft System and Number 11 Landing Gear Consumables None NOTE During the following procedures do not actuate the brake system TASK INSTRUCTIONS 1 Raise the aircraft on jac...

Page 555: ...CON A5 MAINTENANCE MANUAL CHAPTER 14 FIGURE 14 22 WHEEL BRAKE ROTOR DETAIL 3 Remove MLG wheel seal cap 4 Remove cotter pin MLG wheel nut wheel and spacer FIGURE 14 23 WHEEL NUT DETAIL 5 Remove brake r...

Page 556: ...and axle are fully removed from the leg RELATED INFORMATION Main Landing Gear MLG Boot Removal on page 14 41 Empty Weight and CG Measurement While on Jackpoint Scales on page 3 32 14 6 1 7 Main Landin...

Page 557: ...60 in lb 3 Reinsert brake rotor into caliper with the printed side of the rotor facing inboard 4 Coat the entire axle with a thin layer of MOLYKOTE grease 5 Slide spacer over the axle and reattach whe...

Page 558: ...42 Empty Weight and CG Measurement While on Jackpoint Scales on page 3 32 14 6 1 8 Main Landing Gear MLG Actuator Removal Use the following task to remove the main landing gear MLG actuator TASK INFOR...

Page 559: ...the bellcrank VERIFICATION METHOD The task is complete when the actuator has been removed RELATED INFORMATION Removal and Installation of Inspection Panels and Fairings on page 3 34 14 6 1 9 Main Lan...

Page 560: ...sembly attaching the actuator to the bellcrank The head should face aft 8 Install the NAS1149C0532R washer and MS21043 5 nut and using 1 2 and 3 8 wrenches torque to 85 in lbf 9 Connect the actuator e...

Page 561: ...side of each MLG axle It is recommended to use ITL 12297 3 Adjust the landing gear UP position by adjusting the limit switch furthest from the rod end until one leg contacts a bumper 4 Adjust until a...

Page 562: ...Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required Wing Jack Point Adapter ICA009750 Parts Required None Aircraft System and Number 11 Landing Gear Consumable...

Page 563: ...rement 4 The measurement on the protractor shall read 3 822 237 5 To adjust the position of the actuator loosen the jam nut on the actuator switch 6 To adjust the landing gear DOWN position adjust the...

Page 564: ...Instructions 14 7 1 1 Nose Gear Inspection Inspect the nose landing gear system TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tool...

Page 565: ...hment hardware is correctly installed refer to the illustration for hardware location 4 Evaluate the nose landing gear doors for smooth operation and excessive play a With the landing gear in the exte...

Page 566: ...gaps or looseness b There are uniform gaps between the edges of the doors and the fuselage joggle c The door flanges rest against each other d Instrument panel position lights indicate correctly e Nor...

Page 567: ...rk 4 Remove the ICA011894 spacer and AV ICON 002 axle 5 Proceed to section Nose Wheel Tire Leak to add sealant to the Nose Wheel 6 Proceed to the Beringer Wheel and Brake Maintenance Manual if doing f...

Page 568: ...nto the NLG fork 4 Apply LOCTITE 243 to the threads of the two AN4C11A bolts and install them through each leg of the NLG fork and into the axle Torque each to 44 in lbf VERIFICATION METHOD Check that...

Page 569: ...f weighting the tail 4 Use two 2 cross head drivers to remove the screw and binding post that attach the forward NLG door these are secured with LOCTITE 222 5 Remove the forward door along with the lo...

Page 570: ...ar leg has been removed RELATED INFORMATION Right Instrument Panel Top Panel Removal on page 8 17 Left Instrument Panel Top Panel Removal on page 8 19 Battery Removal and Installation on page 6 37 14...

Page 571: ...If the NLG fork steering bearing is not in place install it before proceeding with the steps below TASK INSTRUCTIONS 1 Locate the NLG leg into position in the NLG box in the aircraft 2 Install the AN7...

Page 572: ...lts and nuts to 322 in lbf 5 Locate the NLG drag link into position in the bracket on the NLG leg and install the ICA007756 wrist pin 6 Install retaining ring S73HW2 100 043 into the groove in the wri...

Page 573: ...n then slide in the 4040RSS3 125MOD 12 spacer 9 Apply LOCTITE 222 to the threads of the AN526C632 40 screw 10 Locate the forward NLG door into position so that the pivot holes align deflecting the spr...

Page 574: ...ORMATION Nose Landing Gear NLG Cam Follower Replacement on page 14 66 Right Instrument Panel Top Panel Installation on page 8 18 Left Instrument Panel Top Panel Installation on page 8 21 Battery Remov...

Page 575: ...holding the cam follower to the ICA010386 centering bracket 6 If needed assemble a new cam follower by applying LOCTITE 603 to the outer diameter of a SFR4ZZ bearing and pressing it into the bore of a...

Page 576: ...e wheel self centers to the in trail posi tion Lower the nose back onto the ground RELATED INFORMATION Nose Landing Gear NLG Leg Assembly Installation on page 14 62 14 7 2 6 Nose Landing Gear Steering...

Page 577: ...N nose gear bearing installation removal tool into position Insert should be placed on the top of the leg with the cup on underneath side of gear leg centered around on bearing Place the all thread in...

Page 578: ...ved 3 Lightly scuff nose gear fork pivot bearing bonding area using 80 grit aluminum oxide sandpaper until no shiny areas are present Remove as little material as possible while sanding so as to avoid...

Page 579: ...r Stephenson MS 122RB release agent to any surface of the ICON nose gear bearing install removal tool that may get adhesive on it The tool should never be allowed to touch any surface to be bonded CAU...

Page 580: ...or 3 to 5 days at 77 F 25 C to achieve full strength An accelerated cure may be made by heating the leg in an oven at 150 F 66 C for one hour 10 After cure ream bore of bearing to diameter 0 7420 0 74...

Page 581: ...s a few times to break in the parts allowing smooth operation 8 Install a new cotter pin once proper operation is achieved 9 Remove the foam block from under the hull or lower the aircraft off the jac...

Page 582: ...re 5 Loosen the Mini Worm Drive Clamp that connects the NLG Actuator Boot the forward side of the NLG actuator Retain all hardware 6 Disconnect the aft connection point of the actuator from bracket at...

Page 583: ...orque bolt to 48 in lbf 2 Slide NLG Actuator boot 119255 over the NLG actuator rod end and secure with large clamp 30 45 9 W5 and small clamp 3808 as shown in the graphic below Torque clamps until the...

Page 584: ...ts flat with no gaps against both the NLG Bell Crank and NLG Drag Link as graphically shown below FIGURE 14 29 NLG TOOLING PIN CAUTION Special care should be given to make sure this forward rig is set...

Page 585: ...ICA009750 Wing Jack Point Adapter Rig Pin Dia 1875 0100 0000 Parts Required None Aircraft System and Number 11 Landing Gear Consumables None TASK INSTRUCTIONS 1 Jack the aircraft up or weight the tai...

Page 586: ...of forward most Reed Switch saddle and rotate the thumb wheel to adjust the actuator such that the rig pin slides freely into position 8 Torque Jam nut to 36 40 in lbs and check that hardware is secur...

Page 587: ...e TASK INSTRUCTIONS 1 Jack the aircraft up or weight the tail so that the nose gear is clear of the ground use a safety block under the forward hull if weighting the tail 2 Connect actuator to Test bo...

Page 588: ...m nut to 36 40 in lbs and check that hardware is secure VERIFICATION METHOD Verify no fuses blown and landing gear light shows positive gear down indication 14 7 2 10Nose Wheel Tire Leak This procedur...

Page 589: ...emove valve core 4 Clean using isopropyl alcohol and wipe clean with lint free cloth 5 Shake bottle of sealant well Before pouring sealant turn the bottle upside down with your finger tip over the spo...

Page 590: ...LANDING GEAR NOSE LANDING GEAR ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 14 RELATED INFORMATION Nose Landing Gear NLG Wheel Removal on page 14 58 Nose Landing Gear NLG Wheel Installation on page 1...

Page 591: ...fication LSA RM Task Specific Training Required No Special Tools Required None Parts Required See task procedures Aircraft System and Number 11 Landing Gear Consumables None NOTE Carefully inspect eac...

Page 592: ...AR AFT NOSE LANDING GEAR DOOR ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 14 3 Verify that the door bushings have been installed into the forward bellcrank pockets as shown Repeat this step for both...

Page 593: ...FT NOSE LANDING GEAR DOOR 14 85 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 14 4 Verify that the door bushings have been installed into the aft bellcrank pockets as shown Repeat this step for both LH...

Page 594: ...a mirror image Repeat for the LH side 6 Install the door forks Install the RH stack up of hardware from the previous step into the RH side of the NLG box as shown with the specified hardware Torque to...

Page 595: ...MANUAL CHAPTER 14 7 Prepare the door stops by installing one helicoil insert into the RH door stop Repeat for the LH side Qty Item No Part No 1 29 MS21043 3 1 30 MS21043 4 1 31 NAS1149C0332R 1 33 NAS...

Page 596: ...NCE MANUAL CHANGE C2 CHAPTER 14 8 Install the door stops from the previous step into the NLG box with the hardware shown Tempo rarily leave the hardware loose allowing the door stop to swing freely Re...

Page 597: ...APTER 14 9 Prepare forward RH bellcrank by pressing pin into bellcrank so that the pin is flush with the aft face of the bellcrank Prepare the forward LH bellcrank so that it is a mirror image of the...

Page 598: ...ard bellcranks from the previous step as shown Install the forward bellcranks into the RH and LH bellcrank pockets as shown using the hardware listed Torque all hardware as specified NOTE Ensure that...

Page 599: ...ER 14 11 Prepare door springs by attaching two spring clips onto the spring Prepare a total of two of these assemblies one for the LH and one for the RH NOTE Ensure the spring is connected to the smal...

Page 600: ...y from the previous step and the RH threaded rod end of the pushrod assembly onto the RH NLG fork using the hardware shown Torque to the specified value Repeat for the mirror image LG side NOTE Orient...

Page 601: ...subassembly to the forward bellcrank Connect the opposite side of the pushrod subassembly to the RH forward bellcrank using the hardware shown Torque to the specification listed Repeat for the mirror...

Page 602: ...hits the pin see Point A in image at the same time as the lower stop hits the pin see Point B in the image It may be necessary to keep pressure on the door in the open position so that the lower stop...

Page 603: ...Install door spring to stud Ensure that the CB200 applied to the click bond stud is fully cured Connect the spring clip to the Click Bond stud and secure with the hardware shown Torque to the specifi...

Page 604: ...4 16 Insert bushings into the RH and LH aft bellcranks Install the aft bellcranks into the RH and LH aft bellcrank pockets as shown using the hardware listed Torque all hardware as specified Qty Item...

Page 605: ...CON A5 MAINTENANCE MANUAL CHAPTER 14 17 Install doors to the bellcranks by loosely installing the RH and LH doors to the bellcranks using the hardware shown Qty Item No Part No 4 2 10F87MTT3 50TL 1 26...

Page 606: ...in the nose landing gear inspection procedure See Nose Gear Inspection on page 14 56 Make adjustments as necessary using the following adjustment options Adjust the position of the door in the bellcra...

Page 607: ...R DOOR 14 99 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 14 VERIFICATION METHOD Inspect the Nose Landing Gear per the inspection procedure See Nose Gear Inspection on page 14 56 RELATED INFORMATION N...

Page 608: ...14 100 LANDING GEAR AFT NOSE LANDING GEAR DOOR ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 14...

Page 609: ...Window Installation Procedure 15 6 Wind Deflector Alignment and Instructions 15 6 Window Out Warning 15 6 Keep Hands Clear 15 6 Open Canopy 15 6 Passenger Warnings and Kinds of Operation 15 7 Registr...

Page 610: ...MAINTENANCE MANUAL CHANGE C1 CHAPTER 15 Registration Numbers 15 12 Light Sport 15 12 Oil Type 15 13 No Step Wing 15 13 Horizontal Stabilizer Tip Locks 15 13 Keep AOA Port Clear 15 13 Fueling Informat...

Page 611: ...equired for general and emergency information operating instructions ground servicing instructions and inspections cautions warnings airworthi ness certificate location and holder company logos and mo...

Page 612: ...TER 15 15 2 Placards and Markings General Maintenance 15 2 1 Interior 15 2 1 1 Fuel Shutoff Located on the overhead console 15 2 1 2 Max Amperage for USB and 12V Accessory Port Located inside of arm r...

Page 613: ...ts 15 2 1 5 Secure Loose Objects Located on the window jamb beneath the removable windows only visible when window is removed There are two per aircraft one on the right side and one on the left side...

Page 614: ...e 15 2 1 9 Wind Deflector Alignment and Instructions Located on the wind deflector There are two per aircraft one on the right side and one on the left side when installed 15 2 1 10 Window Out Warning...

Page 615: ...on Located near the front of the overhead canopy 15 2 1 14 Registration Numbers Located on center console of cockpit NOTE Registration numbers are for illustration only Your aircraft registra tion num...

Page 616: ...CE MANUAL CHANGE C1 CHAPTER 15 15 2 1 16 Do Not Jump Start Located under battery charging terminals on right inside surface of fuselage near passenger rudder pedals 15 2 1 17 Fuses Located on overhead...

Page 617: ...e handle 15 2 1 20Parachute Activation Instructions Located on the overhead console just in front of the parachute activation handle 15 2 2 Exterior 15 2 2 1 Canopy Handle Located on the center of the...

Page 618: ...ON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 15 15 2 2 3 Ballistic Parachute Passenger Warning Located near each entrance to the cockpit 15 2 2 4 Parachute Egress Located around the perimeter of the par...

Page 619: ...Located on both wing tips near the trailing edge on top and bottom surfaces total of four locations 15 2 2 6 Wing Lock Located on bottom center wing near wing fold joint forward of the locking handle...

Page 620: ...f the empennage below the vertical tail NOTE Serial number is for illustration only Your aircraft serial number will be different 15 2 2 10Registration Numbers Located on the left and right sides of t...

Page 621: ...of the oil door of the engine cowling 15 2 2 13No Step Wing Located on the upper center wing left and right side toward the leading edge 15 2 2 14Horizontal Stabilizer Tip Locks Located on the unders...

Page 622: ...anopy on the pilot side near the fuel filler cap 15 2 2 17Propeller Warnings Located on either side of the propeller on the flap fence and on the trailing edges of the Seawings below the propeller Lef...

Page 623: ...PLACARDS AND MARKINGS PLACARDS AND MARKINGS GENERAL MAINTENANCE 15 15 CHANGE C1 ICON A5 MAINTENANCE MANUAL CHAPTER 15 On Left Hand Top Trailing Edge of Seawings Below Propeller...

Page 624: ...15 16 PLACARDS AND MARKINGS PLACARDS AND MARKINGS GENERAL MAINTENANCE ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 15...

Page 625: ...16 29 Inspect Engine Mount 16 30 Inspect Throttle Control for Proper Travel and Security 16 32 Grease Coil Pack Connections 16 39 Engine Air Filter 16 43 Inspection Instructions 16 43 Air Filter Clea...

Page 626: ...Cooler and Thermostat Removal 16 79 Oil Cooler and Thermostat Installation 16 80 Fuse Box 16 83 Fuse Box Description 16 83 Fuse Box Diagram Schematic 16 83 Inspection Instructions 16 84 Inspect Regula...

Page 627: ...PROPULSION 16 3 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 16 Install Spinner Dome 16 106...

Page 628: ...s to provide the commanded response The interface is simple and seamless for the pilot automating the process of adjusting fuel air mixture and ensuring optimal performance Move the throttle and the e...

Page 629: ...IGURE 16 1 VIEW LOOKING DOWN AFT RHS OIL TANK NOT SHOWN CYL 1 CYL 3 ENGINE MOUNT AIRBOX FUEL RAIL FUEL RETURN LINE FUEL SUPPLY LINE THERMOSTAT RADIATOR INLET COOLANT HOSE PROPELLER SHAFT GEARBOX COVER...

Page 630: ...R 16 FIGURE 16 2 VIEW LOOKING DOWN FWD LHS OIL TANK NOT SHOWN CYL 4 CYL 2 OIL FILTER COOLANT OVER FLOW BOTTLE STARTER HARNESS SPARK PLUG FUEL SUPPLY LINE FUEL RAIL COVER COOLANT EXPANSION TANK TEMPERA...

Page 631: ...ructions to perform a test run on the Rotax 912 iS Sport 912 i S 2 engine TASK INFORMATION Type of Maintenance Line Level of Certification Owner Pilot Task Specific Training Required No Special Tools...

Page 632: ...vent steam locks in the cooling and fuel system after shut down 8 Shut engine down NOTE Shut engine down to reduce likelihood of unintended start by someone else NOTE On switching off the engine switc...

Page 633: ...e 16 51 Grease Coil Pack Connections on page 16 39 Install Fuse Box and Regulators on page 16 89 Install Fine Fuel Filter on page 10 33 16 1 3 2 ECU Troubleshooting Use the following table for ECU err...

Page 634: ...tors at the fuse box and the connectors from the engine harness to the jumper visually inspect for corrosion or any type of poor connection such as a push pin or receptacle Pay particular attention to...

Page 635: ...e Manual Check and adjust throttle rigging See Inspect Throttle Control for Proper Travel and Security on page 16 32 Engine Ambient Pressure Defective connection sensor connection Check the wiring and...

Page 636: ...CU connection loose Low ECU bus voltage Reseat the ECU connectors Check corresponding injector connection on fuse box See Rotax 912 iS Sport 912 iS 2 Heavy Maintenance Manual Consecutive Test While Ge...

Page 637: ...of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 13 Propulsion Consumables None CAUTION...

Page 638: ...cowl upward 3 Disconnect the ELT and transponder antennas from the electrical harness by disconnecting the coax connectors from the inside of the cowl Remove cowl completely 4 Remove the LHS and RHS m...

Page 639: ...NTENANCE MANUAL CHAPTER 16 FIGURE 16 5 REMOVING EXHAUST FAIRINGS 5 Remove the LHS and RHS fan shroud by removing countersunk screws using a 15 Torx driver There is one screw on the RHS and two on the...

Page 640: ...Engine on page 16 21 Engine Removal on page 16 19 Oil Cooler and Thermostat Removal on page 16 79 Oil Cooler and Thermostat Installation on page 16 80 Coolant Overflow Bottle Removal on page 16 61 Coo...

Page 641: ...a Apply LUBRICANT and install one countersunk screw with a 15 Torx driver b Apply LUBRICANT and install three 10 32 button head screws with 20 Torx driver c Torque to 26 in lb FIGURE 16 7 LH FAN SHRO...

Page 642: ...ton head screws using a 20 Torx driver Apply LUBRICANT and torque to 26 in lb 4 Position the top engine cowl over the engine and connect the ELT and transponder coax connec tors 5 Use a 15 Torx driver...

Page 643: ...ransmitter Antenna Assembly on page 13 55 16 1 4 3 Engine Removal This task should be used to safely remove the Rotax 912iS from the aircraft TASK INFORMATION Type of Maintenance Heavy Level of Certif...

Page 644: ...wo coolant hoses from right and left side of radi ator and two coolant hoses at forward lower center of firewall bulkhead 15 Remove the hose clamps and insulating tape wrap at the three firewall cable...

Page 645: ...gine Oil Check and Replenish on page 16 77 Remove Engine Cowlings on page 16 13 A5 Specific Oil Change Procedures on page 16 78 Engine Coolant Replacement on page 16 57 Engine Mount Removal on page 16...

Page 646: ...gure 16 9 The fitting should be roughly parallel with the engine oil pan NOTE The orientation will be checked again with the engine installed 2 Verify the torque value on the oil return line fitting T...

Page 647: ...ely use tape to temporarily hold them in place 9 While lowering the engine into position guide the engine harnesses along the correct path through and around the engine mount and then through the appr...

Page 648: ...ct the three cannon plugs on top of fuse box 19 Connect the regulator connectors one on each side of fuse box 20 Connect the fuel pump connectors in between the main bulkheads located near lower cente...

Page 649: ...ch is used on the oil tank fitting while torqueing Damage to oil tank may occur if it s not used FIGURE 16 14 ENGINE OIL TANK RETURN HOSE FITTING TORQUEING AND 7 8 12 POINT CROWS FOOT SPECIAL TOOL 31...

Page 650: ...and Replenish on page 16 77 Inspect Throttle Control for Proper Travel and Security on page 16 32 Engine Test Run on page 16 7 Engine Mount Installation on page 16 29 Install Engine Cowlings on page 1...

Page 651: ...aintenance Manual for verification methods RELATED INFORMATION Interval Maintenance Operational Hours on page 3 4 Interval Maintenance Calendar Intervals on page 3 5 Remove Engine Cowlings on page 16...

Page 652: ...ater pump fittings as shown in the upper image of Figure 16 15 FIGURE 16 15 THERMOSTAT SHOWN REMOVED FOR CLARITY 3 Loosen the hose clamp and remove thermostat radiator coolant hose where it attaches t...

Page 653: ...ne mount from the engine VERIFICATION METHOD The procedure is complete when the steps have been finished RELATED INFORMATION Engine Removal on page 16 19 16 1 4 7 Engine Mount Installation Use the fol...

Page 654: ...g at the thermostat Figure 16 16 3 Connect the two coolant hoses where they attach to the lower water pump fittings as shown in the upper image of Figure 16 15 Rotate the hose clamps on the hoses so t...

Page 655: ...es None TASK INSTRUCTIONS 1 Remove engine cowl muffler exhaust headers and exhaust shields See Remove Engine Cowl ings on page 16 13 2 Visually inspect the engine mount and all its inclusive hardware...

Page 656: ...tall cowl muffler exhaust headers and exhaust shields See Remove Engine Cowlings on page 16 13 VERIFICATION METHOD Completion of the instructions above verify that the engine mount is acceptable RELAT...

Page 657: ...cial Tools Required Second person Parts Required None Aircraft System and Number 13 Propulsion Consumables None TASK INSTRUCTIONS 1 Remove engine cowling See Remove Engine Cowlings on page 16 13 It is...

Page 658: ...16 34 PROPULSION ENGINE ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 16 FIGURE 16 20...

Page 659: ...PROPULSION ENGINE 16 35 CHANGE C2 ICON A5 MAINTENANCE MANUAL CHAPTER 16 THROTTLE ASSEMBLY...

Page 660: ...E ASSEMBLY EXPLODED VIEW NOTE ASN 49 and below use a different THROTTLE CABLE BRACKET than shown 2 Remove throttle bezel See Throttle Handle and Bezel Removal on page 8 10 3 Have a helper in the cockp...

Page 661: ...prevent cable from moving 6 Check in the idle position that the throttle lever has at least 0 50 inches of clearance to full travel In cockpit retract throttle handle to contact AFT stop idle positio...

Page 662: ...Adjust position of cable in cable fixation fastener as required See Figure 16 24 FIGURE 16 24 THROTTLE CABLE FIXATION FASTENER 9 When cable adjustment is complete torque cable fixation fastener to 35...

Page 663: ...be used to reapply dielectric grease to the primary side of the ignition coil packs TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special T...

Page 664: ...6 25 ROTAX 912IS SHOWN WITH IGNITION COIL PACKS IDENTIFIED TASK INSTRUCTIONS 1 Turn master switch OFF Remove ignition key 2 Remove engine cowl See Remove Engine Cowlings on page 16 13 3 Remove two M5...

Page 665: ...n access to the primary side of the coil pack Figure 16 27 Remove spiral wrap as necessary NOTE The secondary side may not need to be disconnected to perform this operation FIGURE 16 27 ENGINE IGNITIO...

Page 666: ...ary to clean the connections 7 Apply bead of GREASE DIELECTRIC on the four spade connectors to seal and lubricate as necessary 8 Reconnect the connectors to the respective coil pack terminals and tigh...

Page 667: ...evaluate the cleanliness of the air filter TASK INFORMATION Type of Maintenance Line Level of Certification Owner Pilot Task Specific Training Required No Special Tools Required None Parts Required N...

Page 668: ...eplaced See Related Information In the event that the filter needs cleaning see Related Information on cleaning the filter RELATED INFORMATION Condition and 100 Hour Inspection Engine and Propeller on...

Page 669: ...RUCTIONS 1 Apply a side load to the exterior surface of the air filter During this operation the filter should not show any gapping at the connection points and should stay securely fastened 2 Apply a...

Page 670: ...ne Level of Certification Owner Pilot Task Specific Training Required No Special Tools Required K N Air Filter Cleaning Kit 99 5000 or 99 5050 Parts Required None Aircraft System and Number 13 Propuls...

Page 671: ...awings platform 2 Use screw driver to loosen air filter worm drive clamp 3 Remove filter and clamp from intake duct flange 4 Clean and oil using K N Recharger Kit per K N Air Filter Cleaning Instructi...

Page 672: ...e Air Filter Replace the K N air filter TASK INFORMATION Type of Maintenance Line Level of Certification Owner Pilot Task Specific Training Required No Special Tools Required None Parts Required Air F...

Page 673: ...on page 16 43 16 1 6 Exhaust System 16 1 6 1 Exhaust System Diagram Schematic FIGURE 16 30 EXHAUST SYSTEM ISOMETRIC VIEW 16 1 6 2 Maintenance Instructions 16 1 6 2 1 Remove Exhaust System Use the fol...

Page 674: ...gine with a 12 mm wrench Anti seize should be present on slip joint into cylinder and slip joint at FWD Muffler See Figure 16 31 FIGURE 16 31 AFT EXHAUST HEADER AND EGT SENSOR 4 Remove AFT muffler hea...

Page 675: ...removing the safety wire from the anti rotation tabs and sliding them apart Clean the slip joint interfaces 13 Repeat steps 2 12 for the LH RH exhaust VERIFICATION METHOD Follow up with Exhaust Syste...

Page 676: ...ngine wire harness from the FWD intake manifolds by removing the M6 screw and washer Save for later step 5 Attach support bracket to header using the noted clamp and hardware 6 Attach other end of sup...

Page 677: ...p joint interfaces c Install AFT headers into the associated muffler The anti rotation tabs should overlap so that the tab on the muffler lies outboard of the tab on the header NOTE The mufflers and h...

Page 678: ...zel lower cowl and engine cowl See Install Engine Cowlings on page 16 16 VERIFICATION METHOD After installation perform an engine test run in accordance with Engine Test Run paying particular attentio...

Page 679: ...oolant grades See Approved Engine Coolant Grades and Capacity on page 2 29 and replenish as necessary with coolant 5 Tighten the radiator cap NOTE The radiator cap must be tightened until the stop lug...

Page 680: ...rts Required None Aircraft System and Number 13 Propulsion Consumables None FIGURE 16 34 OIL SYSTEM INSTALLATION WITH HOSES AND HARDWARE SHOWN TASK INSTRUCTIONS 1 Remove engine cowling See Remove Engi...

Page 681: ...ication of completion RELATED INFORMATION Condition and 100 Hour Inspection Operational Inspection on page 3 25 Remove Engine Cowlings on page 16 13 Install Engine Cowlings on page 16 16 16 1 7 2 Main...

Page 682: ...sure it is cool NOTE Only use specified coolant See Approved Engine Oils and Capacity on page 2 27 TASK INSTRUCTIONS 1 Remove the top cowling 2 Place a bucket under the engine bay drain hole on the r...

Page 683: ...that connects the coolant thermostat to the radiator inlet see Figure 16 36 Loosen the radiator hose clamp at the thermostat and pull the hose off the thermostat housing b Drain the coolant into the...

Page 684: ...em as follows a Locate the two ECS hoses where they attach to the forward face of the thermostat See Figure 16 36 b Loosen the hose clamps and pull both hoses off the thermostat c Turn on the master s...

Page 685: ...or until the coolant temperature starts to rise 14 Shutdown the engine and allow it to cool 15 Verify that there are no coolant leaks looking specifically at the hose connections that were disturbed 1...

Page 686: ...of cutouts where stress is highest If damage is found remove the bracket by removing the two M8 and on M10 screws that attach it to the gearbox 5 Inspect the yellow Tygon and black silicon hoses that...

Page 687: ...rea of the bracket and clean with isopropyl alcohol c Bond the anchor to the bracket with Click Bond CB200 adhesive as shown Allow to cure for 2 hours FIGURE 16 37 COOLANT OVERFLOW BOTTLE 2 If install...

Page 688: ...and attach it to the bottom nipple of the bottle Secure with a TY24MX cable tie as shown in Figure 16 39 b Cut a 42 inch length of 552K25 Tygon tubing and install tubing on the bottle cap hose fitting...

Page 689: ...se to the nipple on the expansion tank and secure using a Ty24MX cable tie b Route the yellow Tygon hose down through the bracket and secure to the bracket s anchor using a TY24MX cable tie Ensure tha...

Page 690: ...E FIGURE 16 42 COOLANT OVERFLOW BOTTLE 8 Fill the overflow bottle to the mid range level with new coolant See Approved Engine Coolant Grades and Capacity on page 2 29 9 Install the engine top cowling...

Page 691: ...ting 2 Disconnect the connector from the AAPTS sensor 3 Disconnect the one ground and two power wires from the starter solenoid 4 Remove the two hoses at the bottom of the oil thermostat using a 13 16...

Page 692: ...SK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 13 Propulsion Consum...

Page 693: ...en the coolant radiator is installed and the oil system can be purged per the procedure in the Rotax 912iS Installation Manual RELATED INFORMATION Engine Oil Check and Replenish on page 16 77 16 1 8 O...

Page 694: ...l System Diagram Schematic FIGURE 16 43 OIL SYSTEM COMPONENTS TOP FWD LHS VIEW OIL TANK TANK THERMOSTAT HOSE OIL COOLER CURTIS OIL VALVE THERMOSTAT ENGINE HOSE ENGINE TANK HOSE RETURN LINE OIL THERMOS...

Page 695: ...CE MANUAL CHAPTER 16 FIGURE 16 44 OIL SYSTEM COMPONENTS BOTTOM FWD LHS VIEW ENGINE TANK HOSE RETURN LINE THERMOSTAT ENGINE HOSE TANK THERMOSTAT HOSE PURGE HOSE VENTILATION CURTIS OIL VALVE DRAIN VALVE...

Page 696: ...3 Maintenance Instructions 16 1 8 3 1 Remove Oil Tank Use the following instructions to remove the oil tank TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM TANK THERMOSTAT HOS...

Page 697: ...a 3 4 wrench to hold tank IN fitting while using a 7 8 wrench to loosen IN line fitting Remove the oil return engine tank hose from the oil tank Cap openings See Figure 16 47 5 Use a 13 16 wrench to...

Page 698: ...N A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 16 FIGURE 16 46 OIL TANK INSTALLATION SOME COMPONENTS NOT SHOWN FOR CLARITY CLAMP WORM DRIVE CLAMP WORM DRIVE CABLE TIE CABLE TIE ENGINE MOUNT PURGE TUBE ENGI...

Page 699: ...MANUAL CHAPTER 16 FIGURE 16 47 OIL TANK INSTALLATION SOME COMPONENTS NOT SHOWN FOR CLARITY VERIFICATION METHOD The task is complete when the oil tank has been removed FITTING HOSE END OIL THERMOSTAT P...

Page 700: ...None TASK INSTRUCTIONS 1 Secure the oil tank to the oil tank mount in the orientation shown in Figure 16 47 using 2X CLAMP WORM DRIVE Torque to 25 30 in lbs NOTE The oil tank must maintain a minimum...

Page 701: ...ce on page 16 26 Engine Removal on page 16 19 Remove Oil Tank on page 16 72 16 1 8 3 3 Engine Oil Check and Replenish Check and replenish the engine lubrication system TASK INFORMATION Type of Mainten...

Page 702: ...and min marks At higher oil level over servicing oil will escape via the venting passage The difference between the max and the min marks is approximately 0 5 quarts 0 47 l WARNING Oil changes are ne...

Page 703: ...nose wheel to maintain a nose height attitude with airplane tail not touching ground 4 Open valve and refer to the Rotax 912 iS Sport 912 iS 2 Maintenance Manual for complete oil change directions VE...

Page 704: ...ion on the thermostat and a 7 8 wrench to turn the B nuts The oil cooler outlet line is attached to the oil cooler with a P clamp 10 32 screw nut and washer remove these as well 6 Using a 3 8 and 1 4...

Page 705: ...on Consumables Parker O lube LOCTITE 243 TASK INSTRUCTIONS 1 Install the restrictor plate as shown Torque fasteners to 13 in lbf 2 Lubricate two 9752K118 644 ID x 087 w 908 Viton o rings with Parker O...

Page 706: ...the B nuts to 200 50 in lbf 7 Install the P clamp that attaches the oil cooler outlet line to the oil cooler using the 10 32 screw nut and washer and torquing to 20 in lbf 8 Ensure the bulb seal on t...

Page 707: ...s on page 16 13 VERIFICATION METHOD The procedure is complete when the oil cooler and thermostat have been installed and the engine check shows good oil pressure and no leaks RELATED INFORMATION Remov...

Page 708: ...ctors TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 13 Propulsio...

Page 709: ...e Regulator A and B wires near the connectors Figure 16 50 Replace the Regulator if any signs of discoloration browning are apparent See Remove Fuse Box and Regulators on page 16 86 FIGURE 16 50 FUSE...

Page 710: ...the following procedure to remove the fuse box and the two regulators TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required...

Page 711: ...three connectors as shown in Figure 16 52 Retain O rings Connector D9069P from fuselage wire harness Connector D9106P from engine LANE B extension wire harness Connector D9104P from engine LANE A ext...

Page 712: ...6 Remove four 8 32 x 0 375 screws and washers to remove fuse box Retain hardware for re installation 7 Remove the ground terminals from the ground studs Retain hardware for re installation Fuse box co...

Page 713: ...a M5 lock nut 15 M4 lock nuts 16 and washers 14 17 12 Feed the regulator wiring out of the strain relief 13 If required repeat Steps 7 12 to remove the second regulator VERIFICATION METHOD The task i...

Page 714: ...tighten the strain relief 4 Secure the fuse box cover with nine M4x16 Allen screws 10 and plastic washers 11 5 Secure the ground terminals to the ground studs For Regulator A use one M4 lock nuts 16...

Page 715: ...o the ground studs with M4 nuts and washers Do not install more than five rings on any single ground stud See Figure 16 53 Terminals T9077 T9079 and T9081 from fuselage wire harness All ring terminals...

Page 716: ...is hollow carbon fiber and fiber glass with UV protection The blade leading edges are equipped with metal erosion shields The two piece hub is made from anodized aluminum NOTE Though the propeller is...

Page 717: ...1 Propeller Assembly Instructions for assembling the Sensenich propeller prior to installation onto the Rotax engine TASK INFORMATION Type of Maintenance Line PROP FLANGE ROTAX 912iS 2X COOLING FAN H...

Page 718: ...vision of Sensenich Propellers document 3B0R5 Please contact ICON Aircraft for proper propeller pitch setting before completion of this step VERIFICATION METHOD Verify proper torquing of clamping fast...

Page 719: ...at the propeller is acceptable to each check specified and check off on the condition inspec tion listing RELATED INFORMATION Condition and 100 Hour Inspection Engine and Propeller on page 3 21 16 2 4...

Page 720: ...Propulsion Consumables ICA012078 LUBRICANT GENERAL PURPOSE Tef Gel SpeedTape or equivalent aluminum pressure sensitive tape 3M 7610 TAPE REFLECTIVE 3M SCOTCHLITE TASK INSTRUCTIONS 1 Ensure spinner dom...

Page 721: ...CELEROMETER INSTALLATION EXAMPLE USING AN EXISTING FUEL RAIL SCREW A PROBALANCER SPORT ACCELEROMETER SHOWN 4 Route accelerometer wire through the oil access door in the engine cowl reinstall the top e...

Page 722: ...16 FIGURE 16 60 ACCELEROMETER WIRE ROUTED THROUGH THE OIL ACCESS DOOR 5 Secure the optical tachometer from the Propeller Balance System to the top of the engine cowl with tape about 9 to 12 inches fro...

Page 723: ...the line of sight of the photo tachometer This blade is now identified as Blade 1 See Figure 16 62 CAUTION Turn propeller only counterclockwise looking FWD NOTE Use a ruler to ensure the reflective ta...

Page 724: ...es the suggested location for installing washers FIGURE 16 63 EXAMPLE OF PROPELLER PROTRACTOR ALIGNMENT AFT LOOKING FWD 13 Install a combination of washers listed in this task to achieve the suggested...

Page 725: ...less than 0 08 IPS 15 Remove all sensors wires and test equipment from the aircraft Remove the top engine cowl 16 Reinstall any screws that may have been used to mount the accelerometer 17 Reinstall...

Page 726: ...nstructions for removing the Sensenich propeller onto the Rotax engine TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required...

Page 727: ...ce Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required Calibrated Torque Wrench Parts Required None Aircraft System and Number 13 Propulsion Consumables None T...

Page 728: ...See Task Instructions Aircraft System and Number 13 Propulsion Consumables None TASK INSTRUCTIONS 1 Remove propeller assembly from engine See Propeller Removal From Engine on page 16 102 2 Perform re...

Page 729: ...wing procedure to remove an existing spinner dome TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required...

Page 730: ...ne and Propeller on page 3 21 Balance Propeller on page 16 95 16 2 5 1 2 Install Spinner Dome Use the following task to reinstall the spinner dome TASK INFORMATION Type of Maintenance Line Level of Ce...

Page 731: ...The fasteners and washer stacks must be reinstalled in the starting condition to maintain proper propeller balance 3 Remove all orientation marks VERIFICATION METHOD The task is complete when the spi...

Page 732: ...16 108 PROPULSION PROPELLER ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 16...

Page 733: ...7 12 Remove Right Wing 17 13 Install Right Wing 17 14 Wing Hang Pin Replacement 17 15 Wing Trailing Edge Light Fence Replacement 17 16 Flaps 17 19 Maintenance Instructions 17 19 Flap Surface Removal 1...

Page 734: ...s associated components and members which support the aircraft in flight Includes spars skins ribs flap and aileron structures and counterbalances control surface hinges integral or mounted aircraft w...

Page 735: ...Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 14 Wing Consumables None TASK INSTR...

Page 736: ...in conjunction with tap tests to inspect wing skins for voids TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required See Man...

Page 737: ...nd lower bond lines for the main spar 5 Conduct a tap test on left hand wing skins in the vicinity of upper and lower bond lines for the aft spar 6 Conduct a tap test on left hand wing skins in the vi...

Page 738: ...ls are secure 5 Check flight control surfaces for axial and radial hinge play VERIFICATION METHOD Ensure each step above is completed to verify wing control surfaces RELATED INFORMATION Inspect Roll R...

Page 739: ...wing fold tube 3 Do a visual inspection through the wing fold ribs and access panels 4 Using a borescope flashlight and viewing mirror as appropriate visually inspect all accessible bond lines for cra...

Page 740: ...TRUCTIONS 1 Inspect position light attached lens condition and seal integrity 2 Fold wings and verify the function of the wing fold sockets and release buttons 3 Inspect fuel vent for obstruction and...

Page 741: ...enter wing skin VERIFICATION METHOD Completing the steps above with everything checking as acceptable accomplishes the general wing inspection 17 3 2 Remove Left Wing Instructions for taking the left...

Page 742: ...echanism by pressing the latch pawl on the wing lock switch then simultaneously pull the wing handle lock down all the way to unlock both locking pins 2 Pull the wing outward about a foot and rest sec...

Page 743: ...electrical harness for lights and fuel vent tube inside the hinge 4 Disconnect the electrical connector from the protruding pigtail 5 Disconnect the AOA high pressure tube and low pressure tube on on...

Page 744: ...e fuselage VERIFICATION METHOD When wing is successfully removed from the airplane this task is complete 17 3 3 Install Left Wing Instructions for installing the left wing onto the airplane TASK INFOR...

Page 745: ...e the avionics tubes electrical harness for lights and the fuel vent tube inside the hinge 7 Connect the electrical connector from the protruding pigtail 8 Connect the AOA tubes high pressure tube and...

Page 746: ...aneously pull the wing handle lock down all the way to unlock both locking pins 2 Pull the wing outward about a foot and rest securely on a ladder 3 Locate the rotating pins in the rotating hinge join...

Page 747: ...and lower U joint pins with clips on inside diameter of U joint 4 Slide the wing inward and leave about a foot separation and rest the wing tip securely on a ladder 5 Secure U joint with retaining rin...

Page 748: ...wrench to remove the ICA010126 wing hang pin from its receptacle in the horizontal tail turning it like a bolt 2 Apply LOCTITE 243 to the threads of the replacement pin and thread it into the receptac...

Page 749: ...bles None NOTE Throughout this procedure apply the methods of the general VHB tape procedure See Related Information TASK INSTRUCTIONS 1 Remove the fence and adhesive tape residue from the trailing ed...

Page 750: ...TENANCE ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 17 VERIFICATION METHOD The procedure is complete when the trailing edge light fence is installed RELATED INFORMATION Use of VHB Tape for Installati...

Page 751: ...Consumables None NOTE There are two styles of flap hinge pin One style retains the pin with snap rings and the other style uses cotter pins Remove the flap pins by removing snap rings XSC 113 or cott...

Page 752: ...Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Aircraft System and Number 14 Wing Consumables None NOTE On new installations the...

Page 753: ...ure 17 2 An NAS1149C0332R washer should be used under each cotter pin FIGURE 17 2 FLAP SURFACE 4 Install the AN4C13A bolt MS21043 4 nut and two NAS1149C0432R washers that attach the flap pushrod to th...

Page 754: ...evel of Certification LSA RM Task Specific Training Required No Special Tools Re None Parts Required None Aircraft System and Number 14 Wing Consumables LOCTITE EA 9394 TASK INSTRUCTIONS 1 There are t...

Page 755: ...alcohol then lightly scuffing bonding surfaces with 80 grip aluminum oxide paper g Mix a suitable quantity of LOCTITE EA 9394 epoxy adhesive per manufacturer s instruc tions h Apply a coat of adhesive...

Page 756: ...wing procedure to remove the wing lock switch mounting plate TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Part...

Page 757: ...truss head screws attaching the wing lock switch plate assembly to the fuselage BL38 Rib See Figure 17 4 3 Pull the plate assembly out of the BL38 Rib and disconnect it from the aircraft electrical h...

Page 758: ...SWITCH ICA008701 CATCH WING LOCK HANDLE ICA009633 SWITCH LIMIT WING LOCK LEVER LH ICA009635 SWITCH LIMIT WING LOCK PAWL LH ICA010840 EXTENDED LATCH PAWL WING LOCK SWITCH ICA013017 MOUNTING PLATE WING...

Page 759: ...ion of the locking pawl is sensed by a micro switch that rides on an hourglass shaped pin pushed by the pawl Push this pin in against its spring and verify that it moves freely As the pin is pushed tw...

Page 760: ...hem each to 13 in lbfwith a T15 Torx driver 6 Install the wing fold lock handle See Wing Lock Handle Installation on page 17 30 RELATED INFORMATION Wing Lock Handle Installation on page 17 30 Wing Loc...

Page 761: ...e two link rods attached to the lock handle with a total of four ICA008144 pivot pins and 98410A110 retaining rings Remove each of these making note of the pin orienta tion b Remove the ICA011333 reta...

Page 762: ...rocedure to install the wing lock handle TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required None Parts Required None Airc...

Page 763: ...he detent ball should run in the groove in the mounting boss e Place a 98090A365 plastic shim on the mounting bass shaft followed by a 9714K999 wave spring and ICA008147 spacer as shown in Figure 17 1...

Page 764: ...17 32 WING WING LOCK ICON A5 MAINTENANCE MANUAL CHANGE C2 CHAPTER 17 FIGURE 17 8 WING LOCK HANDLE FIGURE 17 9 WING LOCK HANDLE FIGURE 17 10 WING LOCK HANDLE...

Page 765: ...d operations taking the wing from the folded to extended position and back Ensure the wing lock handle assembly operates freely with detents in appropriate posi tions Visually confirm the mechanism lo...

Page 766: ...ee Wing Lock Switch Mounting Plate Removal on page 17 24 3 Remove the affected components from the wing lock switch mounting plate discarding any retaining clips 4 Install lock handle catch into lock...

Page 767: ...clips Ensure that new retaining clips are used 7 Prepare the ICA010840 extended latch pawl by applying 76475A52 PTFE tape 8 Install the extended latch pawl into the lock mechanism with two ICA008395...

Page 768: ...unting Plate Removal on page 17 24 Wing Lock Switch Mounting Plate Installation on page 17 26 Wing Lock Handle Removal on page 17 28 Wing Lock Handle Installation on page 17 30 17 5 1 6 Wing Lock Catc...

Page 769: ...he handle in the up and locked position See Figure 17 11 FIGURE 17 11 WING LOCK CATCH 2 Use a 3 16 hex wrench to remove a set screw from one end of the housing Use care not to lose the spring and ball...

Page 770: ...ousing VERIFICATION METHOD From the up and locked position unlatch the handle locking pawl and pull the handle down The force needed to displace the handle from the grasp of the lock catch should be 7...

Page 771: ...nism Description 18 2 Troubleshooting 18 3 Wing Fold Mechanism 18 3 Wing Fold Procedure 18 3 Wing Extend Procedure 18 4 Wing Fold Extend Additional Information 18 6 Inspect Wing Pins 18 7 Wing Fold Me...

Page 772: ...itates and or controls the on ground movement of the main wing structure and securing of wings for transport in the folded position Includes mechanisms linkages actuators locks and indicating warning...

Page 773: ...Aircraft System and Number 15 Wing Fold Mechanism Consumables None The manual wing fold system allows the wings to be rotated and folded back along the fuselage reducing the A5 width from approximate...

Page 774: ...hile top of wing will appear to be past vertical 7 Walk the wing aft to the horizontal tail while being careful to keep the wing lower surface aligned vertically in order to prevent contact with the S...

Page 775: ...elease the release pin and lower wing to carry position NOTE Be prepared to hold the weight of the wing when the release pin is pushed Failure to hold the wing up may result in the wingtip contacting...

Page 776: ...compartment can help offset this characteristic The wing fold lock handle has three mechanical latch mechanisms one latch and two ball detents There are two switches on each wing for the wing latch ha...

Page 777: ...ins Check for excess play in the wing pins TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required Caliper and or Micrometer P...

Page 778: ...18 8 WING FOLD MECHANISM TROUBLESHOOTING ICON A5 MAINTENANCE MANUAL CHANGE C0 CHAPTER 18 FIGURE 18 1 WING PINS LOCATION FIGURE 18 2 WING PIN DIMENSIONAL CHECKS...

Page 779: ...erial in the joint Each wing pin has a mating bushing on the inboard side of the wing joint NOTE The wing pins and bushings are not easily replaceable Metal shav ings in the grease is a symptom of wea...

Page 780: ...ptable If not then contact ICON Aircraft for further information Any cracks found in the wing pins or bushings should be investigated further Do not fly the airplane and contact ICON for further instr...

Page 781: ...through two intermeshing bellcranks The bellcrank on the outboard side of the joint has a ball bearing that serves as a roller to guide the two bellcranks together during the wing fold operation Perfo...

Page 782: ...mble apply a thin coat of MOLYKOTE to the pin install a new MS27640 3A bearing and press the pin through the bellcrank and bearing The head of the pin should face aircraft aft 5 Install the 98410A110...

Page 783: ...ng the wing tip to ensure proper engage ment and retention of the pin CAUTION Be sure to support the wing in case of failure The wing should move slightly but should not contact the Seawing 2 Looking...

Page 784: ...firm that the slide bushing assembly is still securely bonded in place and is not able to slide or rotate 6 Ensure the extension cap spring is still fastened to the slide tube 7 Validate that the wire...

Page 785: ...14 Harness Description 19 14 Harness Diagram Schematic 19 14 Inspection Instructions 19 14 Harness Inspection Instructions 19 14 Maintenance Instructions 19 15 Harness Installation 19 15 Extraction R...

Page 786: ...RACHUTE SYSTEM IPS ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 19 Maintenance Instructions 19 34 Activation System Installation 19 34 RELATED INFORMATION Condition and 100 Hour Inspection Parachute o...

Page 787: ...associated brackets and hardware The parachute is a non steerable round parachute used in conjunction with a three point harness assembly to safely descend the planes occupants in an emergency The par...

Page 788: ...19 4 ICON PARACHUTE SYSTEM IPS DIAGRAM SCHEMATIC ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 19 19 2 Diagram Schematic...

Page 789: ...placards 2 Internal Inspection a Ensure the detent pin with the REMOVE BEFORE FLIGHT flag is installed into the acti vation handle b Check the security of the Rocket to the Rocket Mount both fasteners...

Page 790: ...e for damage or abnormalities h Confirm text on the placards is legible 3 If any discrepancies are detected in the preceding instructions the discrepancies must be recti fied in order to consider the...

Page 791: ...ackage installed in the parachute bay is enclosed under the Egress Panel The parachute package contains a round non steerable parachute used for recovery of the aircraft and its occupants 19 4 2 Parac...

Page 792: ...rnal placards 2 Internal Inspection a Inspect the parachute release pin and tether for security Verify the surgeon s knot is taught and properly holding release pin in place b Check the deployment bag...

Page 793: ...g from the rocket cone and GENTLY pull the cable form the igniter rocket cone WARNING At the igniter only 25 30 lbf is required to ignite the rocket assembly 3 Remove rocket cone and install safety wi...

Page 794: ...stallation Use the following tasks to install the parachute package TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Special Tools Required No...

Page 795: ...stallation they will need to be reinstalled and secured Secure pins with 2 and 1 knot using Type 2 GLAZED 4 ply thread NOTE Release pins are installed by BRS prior to delivery FIGURE 19 3 CURVED RELEA...

Page 796: ...the flap using Velcro along the top left edge of the parachute deployment bag FIGURE 19 5 SIDE FLAP CONTAINING COLLAR LINE AND INCREMENTAL HARNESS NOTE Items are secured under flap when system is del...

Page 797: ...KAGE 19 13 CHANGE C1 ICON A5 MAINTENANCE MANUAL CHAPTER 19 RELATED INFORMATION Removal and Installation of Inspection Panels and Fairings on page 3 34 Cockpit Panels Removal and Installation on page 3...

Page 798: ...vlar bridles parachute retaining straps and all mounting hardware The harness system has three attachment points used to suspend the aircraft and its occupants under the canopy 19 5 2 Harness Diagram...

Page 799: ...e the full length of the harness is free of damage and fraying 3 Check the three attachment points for security damage and abnormalities VERIFICATION METHOD Harness is secure at all locations and free...

Page 800: ...Retaining Strap A5 007596 22 Bridle Kevlar A C End Compact Tang 007596 23 Bridle Kevlar A C End Compact Tang ICA009063 PIN TIE OFF CAP VH 62 S16 Retaining Ring Internal Light Duty 316ss 656x 0118 Airc...

Page 801: ...ining ring FIGURE 19 8 A END OF HARNESS ATTACHMENT POINT STARBOARD FORWARD 3 Attach the A end of the forward harness to the mounting bracket PORT side of the aircraft with the pin and the retaining ri...

Page 802: ...e FORWARD PORT and STARBOARD harnesses into the parachute bay to be S folded with the STARBOARD rear attachment point harness and routed to the 1 2 quick link then attached to the riser later in the p...

Page 803: ...ployment bag Rocket collar and lanyards can also be seen FIGURE 19 13 HARNESS ROUTING AFT PORT HARNESS TO PARACHUTE BAY 9 Connect harnesses with 1 2 quick link Riser can also be seen on the right side...

Page 804: ...e S folded harnesses together as a package fixed with 2 two 10 75 cable ties into the parachute bay 11 Insert the harness package into the space between parachute and parachute cover Three harnesses w...

Page 805: ...e sure that bridles are neatly S folded and will be free from restrictions during recovery system deployment VERIFICATION METHOD The procedure is complete when the harness has been successfully instal...

Page 806: ...xtraction Rocket 19 6 1 Extraction Rocket Description The extraction rocket system is comprised of the rocket motor rocket sleeve rocket motor igniter and mounting hardware Once activated a high power...

Page 807: ...es None TASK INSTRUCTIONS 1 Ensure the detent pin with the REMOVE BEFORE FLIGHT flag is installed into the activation handle 2 Check the security of the Rocket to the Rocket Mount both fasteners in th...

Page 808: ...041 TASK INSTRUCTIONS 1 Install the detent pin with the REMOVE BEFORE FLIGHT flag into the activation handle 2 Carefully remove screw retaining activation cable into igniter Unscrew the cone adapter...

Page 809: ...4 2 Extraction Rocket Assembly and Installation Use the following tasks to install the extraction rocket system TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific T...

Page 810: ...after tightening the two bolts it is acceptable to use spacer to fully secure the rocket to the bracket FIGURE 19 16 SECURE ROCKET TO ICON A5 ROCKET MOUNT BRACKET 2 Fasten the rocket mount into the pr...

Page 811: ...e remaining length should be looped and secured with the small cable ties supplied The rocket lanyards should be routed alongside of rather than over the top of the rocket They MUST NOT be routed unde...

Page 812: ...flap of the deployment bag using the installed Velcro fasteners at the top side of the deployment bag FIGURE 19 21 DEPLOYMENT BAG LEFT SIDE FLAP 7 Connect rocket collar to the rocket tube Insert and t...

Page 813: ...e procedure was completed when the component has been installed and the safety pin and flag are installed on the activation handle RELATED INFORMATION Removal and Installation of Inspection Panels and...

Page 814: ...the end of the actuator Put a drop of LOCTITE Blue 242 threadlocker on the threads of 10 24 stainless steel screw Install screw through the unthreaded end of the actuator first with exterior tooth st...

Page 815: ...rocket to fire 3 Grasp the launch tube cone secure it with 2 two screws 10 24 x 3 8 PH with a drop of LOCTITE Blue 242 threadlocker A torque value of 1 5 lb ft should be used to tighten this screw Ens...

Page 816: ...9 FIGURE 19 26 ACCESS HOLE PLUG VERIFICATION METHOD The procedure is complete when the rocket has been successfully armed and all components are secure RELATED INFORMATION Removal and Installation of...

Page 817: ...he recovery system The system consists of a cockpit handle an enclosed activation cable that connects cockpit handle to the extraction rocket ignition 19 7 2 Activation System Diagram Schematic 19 7 3...

Page 818: ...a relatively cooler area for example fwd of the bulkhead near the activation handle Compare color brightness and texture Replace activation line if there is any variation between these two sections 3...

Page 819: ...the activation handle to the overhead console by position the handle tang in line with the two Click Bond studs and securing with self locking hex nuts Place safety pin with REMOVE BEFORE FLIGHT flag...

Page 820: ...ute the activation assembly Apply the second cable tie to secure the activation housing to the cable tie mount The second cable tie is located on the front side of the center wing skin FIGURE 19 29 SE...

Page 821: ...the activation cable will be in position to connect to the launch tube cone at the rocket mounting point WARNING Confirm that the safety pin and flag are installed in the activation handle before con...

Page 822: ...19 38 ICON PARACHUTE SYSTEM IPS ACTIVATION SYSTEM ICON A5 MAINTENANCE MANUAL CHANGE C1 CHAPTER 19...

Page 823: ...RAL REPAIR 20 1 CHANGE C0 ICON A5 MAINTENANCE MANUAL CHAPTER 20 STRUCTURAL REPAIR Description 20 2 General Bonded Fastener Replacement 20 3 General Bonded Fastener Removal 20 3 General Bonded Fastener...

Page 824: ...w for any structural repairs other than what is included in this chapter to be made to the aircraft without prior consent Any structural repairs needed must be coordinated and approved by ICON through...

Page 825: ...cedure below TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Required No Specific Tools Required None Parts Required Many bonded fasteners are used in th...

Page 826: ...ansfer to unintended areas TASK INSTRUCTIONS 1 Cut a conformal mask from silicone rubber sheet 0 25 inch thick The mask should extend a minimum of 3 inches beyond the fastener in all directions In the...

Page 827: ...on Install disbonded or damaged bonded fasteners and any remaining adhesive using the procedure below TASK INFORMATION Type of Maintenance Line Level of Certification LSA RM Task Specific Training Req...

Page 828: ...SK INSTRUCTIONS 1 Prepare and clean the substrate in the area to be bonded in accordance with the Click Bond CBPS 206 Rev E procedure 2 Loosely install the replacement fastener in the location specifi...

Page 829: ...Chapter 21 PAINTING AND COATINGS 21 1 CHANGE C0 ICON A5 MAINTENANCE MANUAL CHAPTER 21 PAINTING AND COATINGS Description 21 2...

Page 830: ...ned paint scheme that reflects radiation from sunlight to prevent the underlying structure from reaching excessive temperatures Any alteration to the paint or paint scheme of the ICON A5 is not permit...

Page 831: ...N A5 MAINTENANCE MANUAL CHAPTER 22 FEEDBACK FORMS Feedback Forms 22 2 Continued Operational Safety Reporting 22 3 Continued Operational Safety Reporting Form 22 4 Change of Address Ownership Form 22 5...

Page 832: ...ide notification to ICON Aircraft about 1 Issues and anomalies identified during the operation or maintenance of the aircraft or in the content of this manual 2 Improvement suggestions or corrections...

Page 833: ...operational or other safety concerns please complete a report via your aircraft reporting portal instructions can be found at the back of the POH ICON Customer Service and Support can also be reached...

Page 834: ...TE CONTACT INFORMATION NAME First Last COMPANY ADDRESS Street Address Street Address 2 City State USA Postal Zip Code Country PHONE NO Main Alternate EMAIL ADDRESS AIRCRAFT INFORMATION MODEL A5 SERIAL...

Page 835: ...MODEL A5 SERIAL NUMBER REGISTRATION NUMBER OLD INFORMATION NAME First Last COMPANY ADDRESS Street Address Street Address 2 City State USA Postal Zip Code Country PHONE NO Main Alternate EMAIL ADDRESS...

Page 836: ...First Last COMPANY ADDRESS Street Address Street Address 2 City State USA Postal Zip Code Country PHONE NO Main Alternate EMAIL ADDRESS AIRCRAFT INFORMATION MODEL A5 SERIAL NUMBER REGISTRATION NUMBER...

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