ICON A5 Maintenance Manual
  1. Manuals
  2. Brands
  3. ICON Manuals
  4. Aircrafts
  5. A5
  6. Maintenance manual

ICON A5 Maintenance Manual

Hide thumbs Also See for A5:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
Table of Contents

Advertisement

Quick Links

Download this manual
MAINTENANCE
MANUAL
MODEL A5
Publication ICA000833, Issue C3
Airplane Registration Number: __________________________________________________
Airplane Serial Number: _________________________________________________________
Date: 28 February 2019
ICON Aircraft / 2141 ICON Way, Vacaville, CA 95688

Advertisement

Table of Contents

Troubleshooting

loading
Need help?

Need help?

Do you have a question about the A5 and is the answer not in the manual?

Questions and answers

Related Manuals for ICON A5

Summary of Contents for ICON A5

  • Page 1 MAINTENANCE MANUAL MODEL A5 Publication ICA000833, Issue C3 Airplane Registration Number: __________________________________________________ Airplane Serial Number: _________________________________________________________ Date: 28 February 2019 ICON Aircraft / 2141 ICON Way, Vacaville, CA 95688...
  • Page 2 ICON Aircraft, 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 ICON Aircraft, Inc.

  • Page 3: Table Of Contents

    ICON Parachute System (IPS) ........
  • Page 4 TABLE OF CONTENTS ICON A5 / MAINTENANCE MANUAL ISSUE C3...

  • Page 5: Revisions

    Manual Revisions ..............1-14 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 6 "Manual Revisions" on page 1-14 1.1.1 Issue C3 Chapter 2 • Updated the Introduction • Updated the Disposable Replacement Parts list • Updated Tire Inflation Pressures Chapter 3 • Updated Landing Gear Condition and 100-Hour Inspection ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 7 Updated Inspect Flap Rigging • Added Flaps Controls Diagram • Updated Pitch Control Diagram • Updated Rigging Roll Controls • Updated Roll Controls Diagram • Updated Install Flap Actuator • Added Rigging Flap Controls section CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 8 • Updated Nose Landing Gear (NLG) Rigging sections • Updated Main Landing Gear (MLG) Rigging sections • Updated Landing Gear Actuator Limit Switch Adjustment Procedure Chapter 15 • Updated Secure Loose Object placard ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 9 • Added Remove Oil Tank • Added Oil Tank Description and Schematic • Added Balance Propeller section • Updated A5 Specific Oil Change Procedures • Updated Install Engine Cowlings • Updated Remove Engine Cowlings • Updated Inspect Engine Mount •...
  • Page 10 Added Fuel Pressure Sensor description • Added Remove Fuel Pressure Sensor • Added Install Fuel Pressure Sensor Chapter 9 • Added Flight Controls description • Added Flight Controls diagram • Added Inspect Rudder Pedal Adjustment Mechanism ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 11 Flap Hinge Repair procedure moved to Chapter 17 Chapter 13 • Added Remove Instrument Cluster • Added Install Instrument Cluster • Renamed Flight Instrument Cluster Gauge Replacement to Replace Instrument Panel Gauge • Added ELT description CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 12 • Updated Engine Mount Inspection task • Added Fuse Box description • Added Remove Fuse Box and Regulators task • Added Install Fuse Box and Regulators task • Added Inspect Regulator Wires task ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 13 All Chapters • Complete layout overhaul Chapter 2 • Update to the logbook instructions • Changed Complete Aircraft Parachute to ICON Parachute System (IPS) Chapter 3 • Updated Maintenance Schedules • Updated Condition Inspections and 100-Hour Inspections • Changed Complete Aircraft Parachute to ICON Parachute System (IPS)
  • Page 14 Updated Check Rudder Rigging • 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 procedure Chapter 14 •...
  • Page 15 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-11 Chapter 19 • Changed Complete Aircraft Parachute to ICON Parachute System (IPS) CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 16 28 February 2019 15. PLACARDS AND 28 February 2019 MARKINGS 16. PROPULSION 28 February 2019 17. WING 28 February 2019 18. WING FOLD MECHANISM 20 April 2018 19. ICON PARACHUTE 28 September 2018 SYSTEM (IPS) ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 17 20. STRUCTURAL REPAIR 20 April 2018 21. PAINTING AND COATINGS 20 April 2018 22. FEEDBACK FORMS 20 April 2018 Applicable to Maintenance Manual Revision: Issue C3 ELATED NFORMATION "Manual Revisions" on page 1-14 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 18 It is the responsibility of the owner to maintain this MM in a current state when it is being used for oper- ational purposes. Owners should contact ICON whenever the revision status of their MM is in question. ELATED NFORMATION "Record of Maintenance Manual Revisions"...

  • Page 19: General

    Lock Washers ..............2-30 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 20 Transportation by Trailer............2-34 ICON A5 / MAINTENANCE MANUAL...

  • Page 21: Introduction

    A5. Repairs, alterations, and maintenance tasks included within this manual are considered minor. Task instructions are valid for any A5 unless a specific Model Year (MY) is called out in the task title. Any repairs, alterations, or maintenance tasks not listed in this manual are considered major. Major repairs, alterations, or maintenance tasks require coordination and approval from ICON Aircraft before any work commences.

  • Page 22: Symbols

    Indicates a potentially hazardous situation or instruction which, if CAUTION not avoided or followed, may result in minor or moderate injury or severely damage the aircraft. Indicates supplementary information that may be needed to fully NOTE complete or understand an instruction. ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 23: General Safety Information

    GENERAL / GENERAL SAFETY INFORMATION General Safety Information The personal safety and health of operators are of primary importance to ICON Aircraft. Maintenance personnel should comply with regulatory standards and best practices for occupational safety. It is important to take adequate precautions regarding the use of any hazardous chemicals specified in your work area.

  • Page 24: Maintenance Terminology And Abbreviations

    Maintenance, inspection, repair, or alterations that are only to be accomplished by the original manufacturer or a facility approved by the original manufacturer of the product. Overhaul Facility Facility specifically authorized by the aircraft or component manufacturer to overhaul the product originally produced by that manufacturer. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 25 Center of Gravity ICON Parachute System Continued Operational Safety Engine Control Unit Exhaust Gas Temperature Emergency Locater Transmitter INOP Inoperable Engine Management System Left Hand Light Sport Aircraft LSA-RM Light Sport Aircraft—Repairman Maintenance CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 26 Maintenance Manual Major Repair and/or Alteration Nose Landing Gear Parachute Installation Manual Radio Frequency Right Hand Trailing Edge Down Trailing Edge Left Trailing Edge Right Trailing Edge Up VSWR Voltage Standing Wave Ratio ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 27: Organization And Structure Of This Manual

    A5 operates. The Inspections chapter gives a list of the inspection tasks developed for the A5. In many cases these inspection tasks are useful in completing condition and 100-hour inspections or to verify the proper completion of a maintenance task.
  • Page 28 GENERAL / ORGANIZATION AND STRUCTURE OF THIS MANUAL ELATED NFORMATION "Line Maintenance, Repairs, and Alterations" on page 2-11 "Heavy Maintenance, Repairs, and Alterations" on page 2-11 "Overhaul" on page 2-11 "Maintenance Levels of Certification" on page 2-11 ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 29: Maintenance System For Light Sport Aircraft

    NFORMATION "Organization and Structure of This Manual" on page 2-9 2.6.4 Overhaul Only ICON Aircraft or an entity approved by ICON Aircraft is authorized to perform overhauls. Overhaul tasks are not defined in this maintenance manual. ELATED NFORMATION "Organization and Structure of This Manual" on page 2-9 "Condition and 100-Hour Inspection—Paperwork"...

  • Page 30: Task-Specific Training

    All maintenance must be performed by factory-authorized personnel who have completed ICON training. At this time, there are no maintenance, repair, or alteration tasks for the A5 which require task-specific training. 2.6.5.2 Minimum Levels of Certification A minimum level of certification is specified for each task in the manual.

  • Page 31: Major Repairs And Alterations

    MM is considered a major repair 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 for compliance and issue a completed MRA Form that includes detailed instructions for completion and an affidavit that the alteration will still result in an aircraft that meets the requirements of the ASTM standards.

  • Page 32: Safety Directives And Continued Operational Safety

    ICON Aircraft’s continued operational safety program, ICA003321 ICON Continued Operational Safety (COS) program, is in place to monitor the safety of the A5 fleet, assess any known or potential safety of flight issues, and determine the method necessary of alerting owners/operators of these issues and the corrective action if necessary.
  • Page 33 GENERAL / SAFETY DIRECTIVES AND CONTINUED OPERATIONAL SAFETY 2-15 ELATED NFORMATION "Safety Directives and Continued Operational Safety" on page 2-14 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 34: Maintenance Schedules

    GENERAL / MAINTENANCE SCHEDULES Maintenance Schedules The A5 has various components and systems that require 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.

  • Page 35: Logbook Instructions

    Complete a review for applicable Notifications (Notifications, Service Bulletins, Safety Direc- tives/Alerts) before completing maintenance tasks. Per 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 or preventive maintenance on the ICON...

  • Page 36: Sources To Purchase Parts

    2-18 GENERAL / SOURCES TO PURCHASE PARTS 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 ELATED NFORMATION https://www.iconaircraft.com ownersupport@iconaircraft.com "Disposable Replacement Parts" on page 2-19...

  • Page 37: Disposable Replacement Parts

    GENERAL / DISPOSABLE REPLACEMENT PARTS 2-19 2.11 Disposable Replacement Parts The following lists the disposable replacement parts and source of supply for the ICON A5. All items may be purchased through ICON Aircraft. Item Part Number Source Main Gear Tires...

  • Page 38: Special Tools

    2-20 GENERAL / SPECIAL TOOLS 2.12 Special Tools The following lists the special tools needed for inspection and maintenance of the A5. All items may be purchased through ICON Aircraft. Tool ICON Part Number Tie-Down Adapter QRP9C0405 Fuel Sumping Tool...
  • Page 39 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 • Borescope • Tensionmeter • Water Rudder Travel Protractor CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 40 14.125±.125 VDC Charge with current capability of at least 4.8 amperes • DIA .250 Rig Pin • DIA .1875 Rig Pin • Plastic Syringe • Flexible PVC Tubing • ITW Tacky Tape • Inclinometer ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 41: Weight And Balance Information

    2.13 Weight and Balance Information The A5 weight and balance can be established using two different methods. The first (and more accu- rate) method uses three jack points—one on each wing and one under the tail skid. The second method uses the aircraft on its landing gear—two main wheels and the nose wheel.

  • Page 42: Equipment List

    Any modifications to the aircraft equipment require the prior approval of ICON Aircraft. Should such work be necessary, ICON will supply any needed weight and balance information and instructions through the Major Repair and Alteration (MRA) process, which is part of the A5 main- tenance program.

  • Page 43: Tire Inflation Pressures

    The main landing gear tires are size 5.00-5, 6-ply aircraft tires with a maximum load rating of 1,285 lb The nose gear tire is size 10-3.50x4, 4-ply aircraft tire with a maximum load rating of 460 lb ELATED NFORMATION "Condition and 100-Hour Inspection—Landing Gear" on page 3-14 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 44: Engine Specifications

    2.16 Engine Specifications The ICON A5 uses a Rotax 912 iS Sport (912iS 2) engine. The engine is a four-cylinder, horizontally opposed, normally aspirated engine configured for a fixed-pitch propeller. Following are some of the specifications and features of the engine.

  • Page 45: Approved Engine Oils And Capacity

    The difference between the max and the min marks is approxi- NOTE mately 0.5 quarts (0.47 l). ELATED NFORMATION "Engine Oil Check and Replenish" on page 16-77 "Engine Coolant Replacement" on page 16-57 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 46: Approved Fuel Grades And Specifications

    Anti-Knock Index is (RON+MON)/2. RON is Research Octane Number and MON is Motor Octane Number. Mixing Fuel Type The A5 fuel system is designed to allow mixing of automotive fuel and AVGAS. ELATED NFORMATION "Condition and 100-Hour Inspection—Operational Inspection" on page 3-25...

  • Page 47: Approved Engine Coolant Grades And Capacity

    SHELL™ Antifreeze Concentrate TEXACO™ Havoline Extended Life Antifreeze VELVANA™ FRIDEX G49 YACCO™ LR-35 Coolant Capacity 0.93 US gallons (approximate) ELATED NFORMATION "Cooling System Inspection" on page 16-54 "Engine Test Run" on page 16-7 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 48: Fasteners

    2.20.1 General The A5 primarily uses stainless steel fasteners throughout the airframe for corrosion resistance. Coun- tersunk Phillips fasteners are used in structural locations. Other hardware is AN aircraft hardware, but of the stainless variety. To the extent possible, all bolts and screws shall be mounted with the heads higher than the rest of the bolt/screw.
  • Page 49 Surface to have threadlocker applied shall be clean and free of grease, oil or contaminants. Surfaces shall be cleaned with isopropyl alcohol prior to threadlocker application. Threadlocker shall only be used within its applicable shelf life, if any, as defined by the manufacturer. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 50 12.1 #10-32 20.8 17.9 1/4-28 43.9 43.4 5/16-24 10.2 82.7 10.8 83.3 3/8-24 15.2 117.7 18.2 120.7 7/16-20 37.0 322.0 11.1 1/2-20 48.5 398.5 14.6 9/16-18 60.0 600.0 18.0 5/8-18 105.0 795.0 31.5 ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 51 Run-On Torque Final Torque #8-36 13.4 #10-32 13.0 26.5 1/4-28 18.7 53.7 5/16-24 17.0 89.5 Specifications within specific inspection or maintenance tasks in NOTE this manual take precedence over the general specifications given here. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 52 2.21 Transportation by Trailer While the A5 with its folding wings and removable tail tips is designed for trailering, it is not designed to be 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 for all components of the airplane.

  • Page 53: Inspections

    Seat Belt Inertia Reel Installation ..........3-40 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 54 System Specific Inspections ........... . .3-59 ICON A5 / MAINTENANCE MANUAL...

  • Page 55: Introduction

    INSPECTIONS / INTRODUCTION Introduction This chapter gives 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.

  • Page 56: Maintenance Schedules

    INSPECTIONS / MAINTENANCE SCHEDULES Maintenance Schedules The A5 has various components and systems that require 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.
  • Page 57 The inspections in the table below must be completed at calendar intervals. Maintenance timing restarts for each item at the last completion. For example, the 2-year maintenance is to be completed every two years. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 58 Compare any weight and balance with the previous one and assess the reason for any differences. Engine Replace hoses (See Rotax Manual) Brakes Replace brake discs (See “Wheel and Brake System Maintenance” on page 14-18.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 59 1. The same inspection (See “Condition Inspections and 100-Hour Inspections” on page 3-9.) is required every 100 flight hours or every 12 calendar months, dependent on which comes first. On completion of the condition inspection or 100-hr inspection both the operation hours and calendar time are reset. Maintenance Comments: CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 60 The overhaul maintenance in the 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 hours, whichever is shorter. There is no limit to the number of overhauls that may be performed and ongoing airworthiness will be governed by the recurring overhauls and inspections.

  • Page 61: Condition Inspections And 100-Hour Inspections

    An airworthy aircraft may be returned to service. All unairworthy inspec- tion issues must be corrected prior to returning the aircraft to service. All data related to unairworthy inspection issues is entered into the ICON Service Request form. Contact ICON owner support if a copy of the form is needed.

  • Page 62: Condition And 100-Hour Inspection-Aircraft Identification And General

    Correct all unsatisfactory items prior to flight S=Satisfactory, U=Unsatisfactory Comments Notifications (Notifications, Service Bulletins, Safety Directives/Alerts) Airworthiness displayed, registration aboard Aircraft identification plate installed 'LIGHT SPORT' placard installed POH/Weight and Balance current and aboard ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 63: Condition And 100-Hour Inspection-Wings

    Wing fold mechanism secure Check wavy springs and U-joint attach rivets Check for excess play in wing pins (See “Inspect Wing Pins” on page 18-7.) Pitot tubes and lines good condition and connections secure CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 64 NFORMATION "Inspect Roll Rigging" on page 9-17 "Inspect Flap Rigging" on page 9-65 "Installation of Wing Tip Lights" on page 6-55 "Inspect Wing Pins" on page 18-7 "Manual Tap Test" on page 3-55 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 65: Condition And 100-Hour Inspection-Fuel Systems

    Fuel tank vent system clear (See “Clear Fuel Tank Vent Line” on page 10-35.) (See “Clear Filler Neck” on page 10-10.) ELATED NFORMATION "Clear Fuel Tank Vent Line" on page 10-35 "Clear Filler Neck" on page 10-10 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 66: Condition And 100-Hour Inspection-Landing Gear

    Check brake fluid level (use only fluid that meets MIL-PRF-83282) Check brake hydraulic lines for leaks and security Test toe brake pedals for sponginess Check rigging of pedals (See “General Brake Line Termination Procedure” on page 14-29.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 67 "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" on page 14-6 "Check Landing Gear Extended Position" on page 14-5 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 68: Condition And 100-Hour Inspection-Forward Fuselage And Hull

    Check flap control operation and flap actuator/bellcrank/cables Check control cables, bellcranks and pulleys for corrosion, attachment, and operation (See “Inspect Control Cables” on page 9-8.) Ensure the cockpit instruments are properly marked Inspect DAC/MSC/instruments/lines for security and condition ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 69 ELATED NFORMATION "Manual Tap Test" on page 3-55 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Inspect Roll Cable Tension" on page 9-13 "Inspect Control Cables" on page 9-8 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 70: Condition And 100-Hour Inspection-Parachute

    Ensure placards text is legible ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Cockpit Panels Removal and Installation" on page 3-36 "ICON Parachute System (IPS)" on page 19-1 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 71: Condition And 100-Hour Inspection-Aft Fuselage And Empennage

    Inspect all control stops for condition and security and proper rigging Static ports clear Inspect yaw rigging (See “Inspect Yaw Rigging” on page 9-85.) Inspect pitch rigging (See “Inspect Pitch Rigging” on page 9-44.) Reinstall tail access panels CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 72 INSPECTIONS / CONDITION INSPECTIONS AND 100-HOUR INSPECTIONS ELATED NFORMATION "Inspect Pitch Rigging" on page 9-44 "Inspect Yaw Rigging" on page 9-85 "Inspect Pitch Cable Tension" on page 9-42 "Inspect Yaw Cable Tension" on page 9-80 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 73: Condition And 100-Hour Inspection-Engine And Propeller

    Remove spinner dome (See “Remove Spinner Dome” on page 16-105.) Torque propeller bolts per Sensenich 3B0R5 Installation Instructions, rev-a8 Reinstall spinner dome (See “Install Spinner Dome” on page 16-106.) Check security and condition of engine grounding wires CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 74 "Air Filter Security Inspection" on page 16-44 "Propeller Installation Onto Engine" on page 16-103 "Inspect Throttle Control for Proper Travel and Security" on page 16-32 "Remove Spinner Dome" on page 16-105 "Install Spinner Dome" on page 16-106 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 75: Condition And 100-Hour Inspection-Avionics And Electrical

    Inspect Rotax fuse box for blown fuses and correct sized fuses are installed Inspect overhead panel for blown fuses and correct sized fuses are installed. See “Replace Overhead Console Fuses” on page 13-18. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 76 INSPECTIONS / CONDITION INSPECTIONS AND 100-HOUR INSPECTIONS ELATED NFORMATION "Bilge Pump Debris Removal" on page 7-6 "Check Bilge Pump Function" on page 6-42 "Calibrate AOA Pressure Transducer" on page 13-25 "Verify Altimeter Calibration" on page 13-83 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 77: Condition And 100-Hour Inspection-Operational Inspection

    "Oil Cooler and Radiator Condition Inspection" on page 16-55 "Approved Fuel Grades and Specifications" on page 2-28 "Inspect Engine Mount" on page 16-30 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Basic Electrical System Inspection" on page 6-31 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 78: Condition And 100-Hour Inspection-Paperwork

    Weight and balance statement in aircraft (Verification Method) Review checklists, record findings, and sign off inspection and maintenance in aircraft logbooks Aircraft A5 S/N__________(serial number) has completed a Condition Inspection as detailed in the checklist above. Aircraft Total Time: _____________________ Name: _______________________________...

  • Page 79: Weight And Balance-General

    FIGURE 3-1 AIRCRAFT REFERENCE LOCATIONS. 3.4.2 Operating Weights and Loading Maximum Occupant Weight 250 lb The seats, interior, Seawings™ platforms steps areas, and safety NOTE restraints were designed to this maximum occupant weight. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 80: Cg Limits And Station Information

    FS 154.75 (located on forward face of wing spar carry-through) Forward CG Limit FS 153.0 Aft CG Limit FS 159.2 See the Weight and CG Envelope Limits figure for further details on NOTE the acceptable operating envelope. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 81: Center Of Gravity Limits

    INSPECTIONS / WEIGHT AND BALANCE—GENERAL 3-29 3.4.4 Center of Gravity Limits FIGURE 3-2 WEIGHT AND CG ENVELOPE LIMITS CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 82: Empty Weight And Cg Measurement

    INSPECTIONS / EMPTY WEIGHT AND CG MEASUREMENT Empty Weight and CG Measurement Use the following procedures to determine the weight and balance condition of the A5. The airplane empty weight includes engine oil and coolant, unusable fuel, hydraulic brake fluid, and installed equipment for the aircraft.
  • Page 83 Verify that the above readings and calculations make sense by comparing them with the Pilot’s Oper- ating Handbook records. Enter the new weight and balance information as a new baseline in the POH. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 84: Empty Weight And Cg Measurement While On Jackpoint Scales

    "Pump Usable Fuel From Fuel Tank" on page 10-8 "Cockpit Floor Board Removal" on page 3-46 3.5.2 Empty Weight and CG Measurement While on Jackpoint Scales Determine the weight and balance condition of the A5 by using the built-in jack points. NFORMATION Type of Maintenance Line...
  • Page 85 "Main Landing Gear (MLG) Wheel and Axle Installation" on page 14-48 "Pump Usable Fuel From Fuel Tank" on page 10-8 "Cockpit Floor Board Removal" on page 3-46 "Landing Gear Excessive Friction Check" on page 14-16 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 86: General Inspection Tasks

    None Parts Required None Aircraft System and Number Consumables None The A5 has the following access panels: • Aft Bulkhead Baggage Panel in the baggage compartment. • Water Rudder Access Panel on the empennage. • Air Rudder Access Panel at the back of the empennage.
  • Page 87 Aileron Access Panel—4X Torx head 8-32 fasteners (on each wing) using a T15 Torx driver. FIGURE 3-3 AFT BULKHEAD BAGGAGE PANEL. ERIFICATION ETHOD Visually inspect that the panel is removed or check that all the fasteners are hand tightened, as desired. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 88: Cockpit Panels Removal And Installation

    "Remove Horizontal Tail Tip Lock Switches" on page 12-6 "Install Horizontal Tail Tip Lock Switches" on page 12-16 "Landing Gear Actuator Limit Switch Adjustment Procedure" on page 14-19 3.6.2 Cockpit Panels Removal and Installation ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 89: Headliner Removal

    Use this procedure to remove the headliner. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 90: Headliner Installation

    "Remove Fine Fuel Filter" on page 10-30 3.6.2.2 Headliner Installation Use this procedure to install the headliner. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 91: Seat Belt Inertia Reel Removal

    "Install Fine Fuel Filter" on page 10-33 3.6.2.3 Seat Belt Inertia Reel Removal Use this procedure to remove the seat belt inertia reel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 92: Seat Belt Inertia Reel Installation

    3.6.2.4 Seat Belt Inertia Reel Installation Uses this task to install the seat belt inertia reel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 93: Baggage Floor Removal

    "Rigging Pitch Controls" on page 9-46 3.6.2.5 Baggage Floor Removal Use the following procedure to remove the baggage floor. NFORMATION Type of Maintenance Line Level of Certification Line Task Specific Training Required Special Tools Required None Parts Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 94: Baggage Floor Installation

    "Remove Fuel Tank (MY18+)" on page 10-15 3.6.2.6 Baggage Floor Installation Use the following procedure to install the baggage floor. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 95: Baggage Sidewall Panel Installation

    "Install Fuel Tank (MY18+)" on page 10-19 3.6.2.7 Baggage Sidewall Panel Removal Use the following task to remove the baggage sidewall panel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 96 Lift the upper edge of the sidewall panel up and off the carbon retaining clips and remove from the aircraft. ERIFICATION ETHOD The task is complete when the baggage sidewall panel has been completely removed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 97 Align the three holes with the underlining structure and install the three push-clip fasteners. Pushing their center buttons in flush once in place, will expand their locking feature. Install the seat belt reels. (See “Seat Belt Inertia Reel Installation” on page 3-40.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 98: Cockpit Floor Board Removal

    The following procedure is used to remove the cockpit floor board. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 99: Cockpit Floor Board Installation

    Use the following procedure to install the cockpit floor board. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 100: Cockpit Sidewall Panel Removal

    Use the following procedure to install the cockpit sidewall panel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 101: Cockpit Sidewall Panel Installation

    None Aircraft System and Number Consumables ® Tef-Gel NSTRUCTIONS Inspect the area behind the panel to ensure nothing is out of place. Locate the panel in position being careful not to scratch anything. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 102: Seat Back Removal

    Remove baggage floor adjacent to the seat back to be removed. (See “Baggage Floor Removal” on page 3-41.) Use a T20 Torx driver and 3/8 wrench to remove the seat back closeout behind the seat to be removed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 103 The following procedure is used to install the seat back. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 104 "Install Fuel Tank (MY18+)" on page 10-19 3.6.2.15 Seat Pan Removal The following procedure is used to remove the seat pan. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 105: Seat Pan Installation

    "Rigging Pitch Controls" on page 9-46 "Seat Belt Replacement" on page 8-3 "Remove Roll Cables" on page 9-28 3.6.2.16 Seat Pan Installation Use the following task to install the seat pan. NFORMATION Type of Maintenance CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 106 Zip up the control stick boot and install the cable tie around the top of the boot, snipping its free end flush with flush-cutters. ERIFICATION ETHOD The task is complete when the seat pan is installed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 107: Manual Tap Test

    NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required A small hammer Parts Required None Aircraft System and Number Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 108 If a defect is found, tap outward from the center of the defect until a change in sound is detected. Mark the area of change and repeat until the entire defect area is identified. Contact ICON for repair instruc- tions.

  • Page 109: Structures

    Firewall Inspection: Using a flashlight and viewing mirror as required, visually inspect firewall for cracks along weld seams, oil stains and coolant/water stains. ERIFICATION ETHOD Verify there are no cracks or other anomalies. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 110 3-58 INSPECTIONS / STRUCTURES ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 111: System Specific Inspections

    See “Propeller” on page 16-92. Wing See “Wing” on page 17-1. Wing Fold Mechanism See “Wing Fold Mechanism” on page 18-1. ICON Parachute System (IPS) See “ICON Parachute System (IPS)” on page 19-1. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 112 3-60 INSPECTIONS / SYSTEM SPECIFIC INSPECTIONS ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 113: Structures

    Use of VHB Tape for Installations and Repairs ........4-12 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 114: Structures Description

    The manual wing fold system allows the wings to be rotated and folded back along the fuselage, reducing the A5 width from approximately 35 feet to 8 feet for trailering and storage. The wing fold mechanism was designed to be simple, allowing one person to complete the task in just a few minutes with no tools required using the procedures described in the Pilot’s Operating Handbook...

  • Page 115: Wheels And Brakes

    The parking brake is intended only for short-term use (<10 minutes) CAUTION while completing tasks such as folding/unfolding the wings. Never leave the aircraft unattended with just the parking brake set. To release the parking brake, move the lever to the “OFF” position. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 116: Rinse After Salt Water Operations

    STRUCTURES / RINSE AFTER SALT WATER OPERATIONS Rinse After Salt Water Operations The structure and many other parts of the A5 are constructed of corrosion proof composite materials. There are, however, many small fittings made up of nickel-plated steel, anodized aluminum, and stain- less steel.

  • Page 117: Overall Exterior Rinse

    If salt water may have entered the engine inlet, direct water into the engine inlet and through the oil cooler and radiator. This water will drain out the cowling outlet and through the drain at the low point of the firewall. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 118: Interior Rinse

    Turn aircraft bilge pump on. Carefully direct flow of water over heater core, rudder pedal assem- blies, rudder lateral torque tubes, and other areas with salt deposits. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 119: Wing Fold Rinse

    Special Tools Required None Parts Required None Aircraft System and Number Consumables None NSTRUCTIONS Unlatch and pull out wing as if to fold it, but do not rotate or walk it back to tail. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 120: Horizontal Tail Tip Rinse

    NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number Consumables None NSTRUCTIONS Remove the horizontal tail tips. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 121: Salt-Away Rinse

    Use Salt-Away product per the manufacturer’s instructions to rinse aircraft using overall exterior rinse procedure. (See “Overall Exterior Rinse” on page 4-5.) ERIFICATION ETHOD Task is done when overall exterior rinse procedure is completed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 122: Corrosion Inhibitor Application

    Nose gear aft door retraction linkages Nose gear self-centering gas spring and cam Nose gear retraction bellcrank and drag link Nose gear leg pivot, forward door pivot, and spring Main gear axle and brake caliper ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 123 All HT tip joint metal parts All wing fold metal parts Canopy latch ERIFICATION ETHOD The task is done when all steps are complete. ELATED NFORMATION "Rinse After Salt Water Operations" on page 4-4 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 124: Use Of Vhb Tape For Installations And Repairs

    Adhesion Promoter 111 to the cleaned mating surfaces. Allow to dry completely prior to the application of tape. Locate the affected component per its associated installation drawing. Contact ICON Aircraft for the appropriate installation drawing as listed below the task steps.
  • Page 125 After the tape is fully cured, pull firmly on the component to ensure that it is bonded properly to the attaching surface. ELATED NFORMATION "Wing Trailing Edge Light Fence Replacement" on page 17-16 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 126 4-14 STRUCTURES / USE OF VHB TAPE FOR INSTALLATIONS AND REPAIRS ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 127: Doors And Windows

    Doors and Windows Description........... 5-2 CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 128 Windows include: the windshield canopy consisting of transparency, frame and removable side windows; and fixed aft windows. Includes items such as: associated door/window structure, transparencies, hinges, latching mecha- nisms, handles, gas struts, seals, controls, and any integral handholds. ICON A5 / MAINTENANCE MANUAL CHANGE C0...

  • Page 129: Electrical System

    Charge Battery ............. . .6-38 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 130 Fuel Level Sensor Replacement ..........6-72 ICON A5 / MAINTENANCE MANUAL...

  • Page 131: Description

    EMS system (engine), if the switching threshold is exceeded. Alternator B is then used to power the aircraft systems and to charge the battery. Both the battery and alternator B are sharing the same electric bus. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 132: Electrical System Wiring Diagrams

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS Electrical System Wiring Diagrams System wiring diagrams for all of the aircraft systems including control sticks, ELT, engine, lighting, flaps, fuel system, avionics and instruments, utility systems, and landing gear. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 133: System Wiring Diagram, Bilge

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.1 System Wiring Diagram, Bilge CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 134: System Wiring Diagram, Control Sticks, Pitch Trim

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.2 System Wiring Diagram, Control Sticks, Pitch Trim ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 135: System Wiring Diagram, Elt

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.3 System Wiring Diagram, ELT CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 136: System Wiring Diagram, Engine Interface

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.4 System Wiring Diagram, Engine Interface ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 137 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 138 6-10 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 139 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-11 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 140: System Wiring Diagram, Exterior Lights

    6-12 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.5 System Wiring Diagram, Exterior Lights ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 141 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-13 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 142: System Wiring Diagram, Flaps

    6-14 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.6 System Wiring Diagram, Flaps ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 143: System Wiring Diagram, Fuel

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-15 6.2.7 System Wiring Diagram, Fuel CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 144: System Wiring Diagram, Gps

    6-16 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.8 System Wiring Diagram, GPS ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 145: System Wiring Diagram, Heater

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-17 6.2.9 System Wiring Diagram, Heater CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 146: System Wiring Diagram, Hour Meter

    6-18 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.10 System Wiring Diagram, Hour Meter ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 147: System Wiring Diagram, Instrument Lighting

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-19 6.2.11 System Wiring Diagram, Instrument Lighting CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 148: System Wiring Diagram, Instrument Signals

    6-20 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.12 System Wiring Diagram, Instrument Signals ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 149: System Wiring Diagram, Interior Lighting

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-21 6.2.13 System Wiring Diagram, Interior Lighting CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 150: System Wiring Diagram, Landing Gear

    6-22 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.14 System Wiring Diagram, Landing Gear ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 151 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-23 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 152 6-24 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 153: System Wiring Diagram, Mode C

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-25 6.2.15 System Wiring Diagram, Mode C CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 154: System Wiring Diagram, Outlets

    6-26 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.16 System Wiring Diagram, Outlets ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 155: System Wiring Diagram, Vhf

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-27 6.2.17 System Wiring Diagram, VHF CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 156 6-28 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 157: System Wiring Diagram, Water Rudder

    ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6-29 6.2.18 System Wiring Diagram, Water Rudder CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 158: System Wiring Diagram, Wing & Tip Switches

    6-30 ELECTRICAL SYSTEM / ELECTRICAL SYSTEM WIRING DIAGRAMS 6.2.19 System Wiring Diagram, Wing & Tip Switches ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 159: Troubleshooting

    Check integrity of all connectors to and from ECU. Inspect condition of wire harnesses for chafing, fraying and damage. ERIFICATION ETHOD Check acceptable condition and security of components behind the Aft Bulkhead Baggage Panel. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 160: Battery Diagnostic

    Battery voltage is 12.6 VDC or Recommended to replace above but the battery is four battery. See “Battery Removal years old and is not capacity and Installation” on page 6-37. tested. Source: (1) Concord document no.5-0171 Rev P. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 161: Electrical System General Maintenance

    Disconnect all ring terminals going to the ignition switch. Discard ignition switch. Connect all ring terminals to the new ignition switch using diagram below. Connect the two push-on terminals to the master switch using the diagram below. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 162: Inspect, Repair, And Secure Wiring Harness With Signs Of Chafing

    Inspect, Repair, and Secure Wiring Harness with Signs of Chafing Use the following procedure to inspect the wiring harness for chafing, security, and condition. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 163 The task is completed when the fuselage and engine wire harness have been inspected and repaired as needed. ELATED NFORMATION "Cockpit Panels Removal and Installation" on page 3-36 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Remove Engine Cowlings" on page 16-13 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 164: Battery

    6.5.1 Battery Description The A5 uses a Concorde, valve regulated lead acid (VRLA) 12V, 24AHR Absorbent Glass 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 batteries are sensitive to overcharging, the recommended charge rate should be kept around 2.25-2.30V/cell...

  • Page 165: Maintenance Instructions

    Install the Battery Hold Down bracket with nut and washer as removed. Hand tighten the nuts ensuring the bracket sits evenly across the battery then torque each side to 44 in-lb with a 7/16 wrench. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 166: Charge Battery

    Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required A 14.125±.125 VDC charge with current capability of at least 4.8 amperes for AGM batteries. Parts Required None Aircraft System 03—Electrical System Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 167 Attach negative charging clamp from charging unit to the negative charging terminal. Turn on the charging unit. Boost-charge battery up to a minimum of 12.6 VDC. Do not exceed 192 amperes charge current. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 168 Turn the master switch ON. Verify that the BATTERY indicator does not stay lit in the annunciator panel. If the battery requires charging after normal aircraft operation, the NOTE battery may be faulty and must be replaced. See “Battery Diag- nostic” on page 6-32. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 169: Bilge Pump

    Bilge Pump Description The A5 has a bilge pump located at the low point on the inside of the 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™...

  • Page 170: Inspection Instructions

    Inspection Instructions 6.6.3.1 Check Bilge Pump Function The following section includes the information necessary to check the function of the bilge pump on the A5. NFORMATION Type of Maintenance Line Level of Certification LSA-RM ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 171: Bilge Pump Removal (My17)

    Verify that bilge pump successfully pumps the water from inside the hull. ELATED NFORMATION "Condition and 100-Hour Inspection—Avionics and Electrical" on page 3-23 6.6.3.2 Bilge Pump Removal (MY17) Use the following procedure to remove the bilge pump (MY17). NFORMATION Type of Maintenance CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 172: Bilge Pump Installation (My17)

    The task is completed when the bilge pump has been removed. ELATED NFORMATION "Remove Fuel Bladder (MY17 Only)" on page 10-11 6.6.3.3 Bilge Pump Installation (MY17) The following task should be used to install the bilge pump (MY17). NFORMATION Type of Maintenance ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 173 FIGURE 6-6 REMOVE BOTTOM SCREEN Slide bottom strainer into place under the mounting flange. Install the pump body onto the bottom strainer by aligning it and rotating clockwise until locked. (See Figure 6-7.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 174 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 Apply Sil-Poxy adhesive around the mounting flange, completely covering the cable tie as shown. (See Figure 6-9.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 175: Bilge Pump Removal (My18+)

    "Install Fuel Bladder (MY17 Only)" on page 10-12 6.6.3.4 Bilge Pump Removal (MY18+) The following procedure should be used to remove the bilge pump (MY18+). NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 176: Bilge Pump Installation (My18+)

    Use the following procedure to install the bilge pump (MY18+). NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required PUMP, BILGE, 12VDC 1.8A, 550GPH ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 177 3M fire barrier (201). Wipe excess sealant extruded from pin holes flush with top side surface of bonding flange. Allow fire barrier to cure for 90 minutes before reinstalling the bilge pump. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 178 Slide one end of the hose onto the bulkhead fitting in the fuselage wall (until flush with the fuselage wall) and the other end onto the bilge pump (until flush with the bilge pump). ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 179 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 clear- ance of .125” from the fuselage roll control cable. Tighten clamps until a seal is achieved. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 180 Connect D9009J connector on bilge pump to D9009P connector on main wire harness. Test that the bilge pump operates normally. Install the fuel tank. (See “Install Fuel Tank (MY18+)” on page 10-19.) ERIFICATION ETHOD The procedure is complete when the fuel tank is installed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 181: Wing Tip Lights

    6.7.3 Maintenance Instructions 6.7.3.1 Removal of Wing Tip Lights These instructions should be used to remove the wing tip lights. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 182 Disconnect D9006J1 and D9006P2 on LIGHT, POSITION & STROBE, LE-RH from D9006P1 and D9006J2 on aircraft wire harness, respectively. Disconnect D9007P on LIGHT, POSITION & STROBE, TE-RH from D9007J on aircraft wire harness. FIGURE 6-13 LEADING EDGE LIGHT ASSEMBLY, LH ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 183: Installation Of Wing Tip Lights

    6.7.3.2 Installation of Wing Tip Lights These instructions should be used to remove the wing tip lights. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None Parts Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 184 Trailing Edge Light Fence Replacement” on page 17-16.) ERIFICATION ETHOD The task is complete when the light is secure. ELATED NFORMATION "Condition and 100-Hour Inspection—Wings" on page 3-11 "Removal of Wing Tip Lights" on page 6-53 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 185: Landing And Taxi Lights

    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 is in the radio bezel. 6.8.2 Landing and Taxi Lights Diagram/Schematic FIGURE 6-15 LANDING AND TAXI LIGHTS DIAGRAM CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 186: Maintenance Instructions

    Use the following instructions to remove the landing and taxi lights. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 03—Electrical System Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 187 Remove 7 8-32 nuts and washers attaching the landing and taxing light to the front fuselage. Keep for re-installation. Remove the LH and RH landing and taxi lights. ERIFICATION ETHOD The task is complete when both landing and taxi lights have been removed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 188: Install Landing And Taxi Lights

    Install LH and RH light assembly onto existing studs as shown using retained washers and nuts. See Figure 6-16. Torque nuts to 13 in-lbs. Check that hardware is secure. Plug D9033P connector on main wire harness into receptacle on LH light. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 189 This task is done when the landing and taxi lights are installed and working. ELATED NFORMATION "Right Instrument Panel Top Panel Installation" on page 8-18 "Left Instrument Panel Top Panel Installation" on page 8-21 "Remove Landing and Taxi Lights" on page 6-58 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 190: Dome Light Switch

    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 overhead console. 6.9.2 Dome Light Switch Diagram/Schematic ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 191 ELECTRICAL SYSTEM / DOME LIGHT SWITCH 6-63 FIGURE 6-17 OVERHEAD CONSOLE AND DOME LIGHT SWITCH CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 192: Maintenance Instructions

    Carefully remove the connectors from short and long posts on SWITCH, SPST, 30A. (See Figure 6-17.) Remove the retaining nut and remove the dome light switch from teh overhead console. ERIFICATION ETHOD The task is completed when the switch has been removed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 193: Install Dome Light Switch

    Install the new SWITCH, SPST, 30A into the overhead console frame and tighten with retaining nut. Torque to finger tight. Connect wire labeled T9924 to the short post of the switch and T9926 to the tall post of the switch as shown in Figure 6-18. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 194 Reinstall the console bezel. (See “Overhead Console Component Replacement” on page 13-15.) ERIFICATION ETHOD Turn the master switch on and verify that the dome light switch correctly controls the dome light. ELATED NFORMATION "Overhead Console Component Replacement" on page 13-15 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 195: Fuel Pressure Sensor

    FUEL PRESSURE SENSOR LOCATION 6.10.3 Maintenance Instructions 6.10.3.1 Remove Fuel Pressure Sensor These instructions should be used to remove the fuel pressure if it shows signs of a leak. NFORMATION Type of Maintenance CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 196 Remove PRESSURE SENSOR. Use backing wrench to hold the fuel pressure sensor adapter in place prior to loosening up the sensor. (See Figure 6-20.) Use a lot of rags to catch any liquid fuel from splattering around CAUTION cockpit. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 197: Install Fuel Pressure Sensor

    "Headliner Removal" on page 3-37 6.10.3.2 Install Fuel Pressure Sensor Use the following instructions to install the fuel pressure sensor. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 198 Turn fuel shutoff valve to the ON position. ERIFICATION ETHOD Pressure check fuel lines with fuel valve in ON position and both pumps running. Ensure no leaks are visible. ELATED NFORMATION "Headliner Installation" on page 3-38 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 199: Fuel Level Sensor

    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 D9039P on the main wire harness. 6.11.2 Fuel Level Sensor Diagram/Schematic FIGURE 6-21 FUEL LEVEL SENSOR INSTALLATION DIAGRAM CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 200: Maintenance Instructions

    Disconnect fuel level sensor connector from d9039p aircraft wire harness. Cut the zip ties securing the wire harness. Disconnect EXTERIOR SUPPLY LINE. See Figure 6-21. Remove 12 AN3C4A BOLT and washers to remove FUEL TANK ACCESS PLATE from the FUEL TANK ACCESS GASKET. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 201 ELECTRICAL SYSTEM / FUEL LEVEL SENSOR 6-73 FIGURE 6-22 REMOVE FUEL TANK ACCESS PLATE Remove the 4 6C37MTT3 SCREW on CLAMP BRACKETS to release the fuel level sensor from Interior supply line. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 202 FUEL TANK ACCESS PLATE using six MS35307 BOLT threaded into blind fasteners on the other side of the FUEL TANK ACCESS PLATE. Remove both ground wire RING TERMINAL attached to the bolts. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 203 MS35307 BOLT in star shaped pattern to 40 in-lbs each. (See Figure 6-24.) The last bolt for RING TERMINAL in the fuel level sensor will be NOTE installed at a later step. Position CLAMP BRACKETS as shown, reinstall CLAMP BRACKETS onto the fuel level sensor. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 204 Attach T9028 and T9026 ring terminals and install AN3C4A BOLT and washer into fuel level sensor, apply LOCTITE 243. Torque to 40-45 in-lbs. Connect the fuel level sensor connector to the aircraft harness. See Figure 6-21. Verify continuity to ground between ring terminal and ground stud. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 205 Apply LOCTITE 425 to OPTICAL SENSOR and install OPTICAL SENSOR into bottom of fuel tank. Torque OPTICAL SENSOR to 12-15 in-lbs. Wrap connector with F4 tape. Secure wiring for OPTICAL SENSOR to fuel tank using zip ties and cable tie mounts. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 206 Step 16 operates as the verification method for this task. ELATED NFORMATION "Baggage Floor Removal" on page 3-41 "Seat Back Removal" on page 3-50 "Baggage Floor Installation" on page 3-42 "Seat Back Installation" on page 3-51 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 207: Environmental Control (Utility Systems)

    Bilge Pump Debris Removal............7-6 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 208: 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 unit with liquid transfer lines to engine radiator, cabin fresh air eyeball vents, ducts, scoops and water/air separator. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 209: Cabin Heater

    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/or Alteration (MRA) process or handled directly by ICON.

  • Page 210: Heater Fan And Core Installation

    Special Tools Required None Parts Required None Aircraft System and Number 04—Environmental Control (Utility Systems) Consumables None NSTRUCTIONS Locate heater core in position if it was removed. Tighten the 6 B-nuts finger tight. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 211 Test that the fan works properly. Run the engine for a few minutes, then check and adjust the coolant level and check for coolant leaks. ELATED NFORMATION "Right Instrument Panel Top Panel Installation" on page 8-18 "Left Instrument Panel Top Panel Installation" on page 8-21 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 212: Maintenance Instructions

    Replace the right baggage floor panel. (See “Baggage Floor Installation” on page 3-42.) Tighten and secure the 4 Torx #20, 10-32 thread flat head screws. ELATED NFORMATION "Condition and 100-Hour Inspection—Avionics and Electrical" on page 3-23 ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 213: Equipment And Furnishings

    Left Instrument Panel Top Panel Installation ........8-21 Instrument Panel Center Spine Removal and Installation......8-22 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 214: Equipment And Furnishings Description

    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 components with instrument mounting provisions, interior cover panels and trim, miscellaneous storage compartments, and associated attachment brackets and hardware. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 215: Equipment And Furnishings General Maintenance

    Remove the seat belt inertia reel.(See “Seat Belt Inertia Reel Removal” on page 3-39.) Use 1/2 and 3/8 wrenches to remove the bolt and nuts securing the outboard end of the belt assembly where it attaches to the outboard longeron. See Figure 8-1. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 216 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 is threaded into a nutplate. See Figure 8-2. FIGURE 8-2 CO-PILOT SIDE SHOWN Installation ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 217: Center Console Bucket Removal

    Use the following procedure to remove the center console bucket. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 05—Equipment and Furnishing Consumables CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 218 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 SCREWS Remove 2X Screws which secure the center armrest. Retain all fastening hardware. See Figure 8-4. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 219 Lift the center console bucket, disconnect the electrical connections and remove. Label the wires for later installation. The connections are: cigarette lighter connectors — T9117(+) and T9119(-); USB power connectors — T9120(-) and T9116 (+); Aux audio in jack — D9063P. See Figure 8-5. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 220: Center Console Bucket Installation

    "GPS Mount and Radio Stack Bezel Removal" on page 8-15 8.2.3 Center Console Bucket Installation Use the following procedure to install the center console bucket. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 221 Terminal T9116 on fuselage wiring harness connects to positive terminal on USB Terminal T9120 on fuselage wiring harness connects to negative terminal on USB FIGURE 8-6 CENTER CONSOLE BUCKET ELECTRICAL CONNECTIONS Install center console bucket. See Figure 8-5. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 222: Throttle Handle And Bezel Removal

    Task Specific Training Required Special Tools Parts Required None Aircraft System and Number 05—Equipment and Furnishing Consumables ® LOCTITE 243™ NSTRUCTIONS Remove center console bucket. (See “Center Console Bucket Removal” on page 8-5.) ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 223 Retain all fastening hardware and handle components. See Figure 8-7. Throttle Handles Screw Apply Thread Locker FIGURE 8-7 THROTTLE HANDLE SCREWS Remove the standoff that is inserted into the throttle lever. Retain hardware. See Figure 8-8. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 224 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 indexing tabs that slide out from the center stack and center console panel assembly. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 225: Throttle Handle And Bezel Installation

    "GPS Mount and Radio Stack Bezel Removal" on page 8-15 8.2.5 Throttle Handle and Bezel Installation Use the following procedure to remove the throttle handle and bezel. NFORMATION Type of Maintenance Line Level of Certification CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 226 CONNECTS TO CONNECTS TO T9105 T9114 T9114 Terminal T9105 Terminal FIGURE 8-10 THROTTLE BEZEL ELECTRICAL CONNECTIONS Install throttle bezel. Slide bezel tabs under radio stack bezel and push bezel into place. See Figure 8-9. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 227: Gps Mount And Radio Stack Bezel Removal

    Remove the GPS mount. If the center console bucket and throttle bezel are still in place. (See “Center Console Bucket Removal” on page 8-5.) (See “Throttle Handle and Bezel Removal” on page 8-10.) CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 228 Use the following procedure to install the GPS mount and Radio stack bezel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 05—Equipment and Furnishings Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 229: Right Instrument Panel Top Panel Removal

    Level of Certification LSA-RM Task Specific Training Required Special Tools Required T15 Torx driver #2 right-angle crosshead driver Eyeball Vent Tool (ITL001563) Parts Required None Aircraft System and Number 05—Equipment and Furnishing Consumables None CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 230: Right Instrument Panel Top Panel Installation

    Remove the vent air hose at right side instrument panel by loosening the worm drive clamp. Remove the right eyeball air valve using ICON eyeball vent tool ITL001563. Remove the 6-32 screw behind the right eyeball air valve with a #2 right-angle crosshead driver.

  • Page 231: Left Instrument Panel Top Panel Removal

    "Landing Gear Actuator Limit Switch Adjustment Procedure" on page 14-19 8.2.10 Left Instrument Panel Top Panel Removal Use the following procedure to remove the left instrument panel top panel. NFORMATION Type of Maintenance Line CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 232 Remove the vent air hose at left side instrument panel top panel by loosening the worm drive clamp. Remove the left eyeball air valve using ICON tool ITL001563. Remove the 6-32 screw behind the left eyeball air valve with a #2 right-angle crosshead driver.

  • Page 233: Left Instrument Panel Top Panel Installation

    Install right eyeball air valve using special tool ITL001563, aligning tooling holes to 6 and 12 o’clock positions. Install Throttle Handle and Bezel. (See “Throttle Handle and Bezel Installation” on page 8-13.) CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 234: Instrument Panel Center Spine Removal And Installation

    8C50MTT3 SCREW, MACH TRH, 6LOBE, CRES, 8-32X.500 Aircraft System and Number 05—Equipment and Furnishings Consumables None NSTRUCTIONS Remove left instrument panel top panel. (See “Left Instrument Panel Top Panel Removal” on page 8-19.) ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 235 REMOVE HANDHOLD SCREWS Remove two screws securing instrument panel center spine to the front of the fuselage. Remove two screws securing center spine to the top of the center console. Retain for reinstallation. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 236 Install right instrument panel top panel. (See “Right Instrument Panel Top Panel Installation” on page 8-18.) Install left instrument panel top panel. (See “Left Instrument Panel Top Panel Installation” on page 8-21.) ERIFICATION ETHOD Task is complete when the center spine has been installed. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 237: Flight Controls

    Pitch Trim Actuator Description..........9-53 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 238 Re-Rigging Rudder Pedals ...........9-103 ICON A5 / MAINTENANCE MANUAL...

  • Page 239: Flight Control System Description

    This includes control cables and pushrods that move through a system of pulleys and bellcranks to move the appropriate control surfaces. Each pilot in the A5 has a control stick. Moving the control stick left-to-right rolls the aircraft in either direction by changing the position of the ailerons.

  • Page 240: Diagram/Schematic

    FLIGHT CONTROLS / DIAGRAM/SCHEMATIC Diagram/Schematic Flap Controls Pitch Controls Roll Controls Yaw Controls Rudder Pedals Control Stick FIGURE 9-1 FLIGHT CONTROL DIAGRAM ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 241: Flight Control System General Maintenance

    The following section contains information needed to inspect the rudder pedal adjust mechanism for correct function. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 06—Flight Controls Consumables None CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 242 RUDDER PEDAL LATCH LOCATIONS UNDER PILOT AND CO-PILOT SEATS. NSTRUCTIONS Remove the floorboard immediately in front of the pilot seat. (See “Cockpit Floor Board Removal” on page 3-46.) Pull the lever under the seat as shown ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 243 Replace the floorboard immediately in front of the pilot seat. (See “Cockpit Floor Board Installa- tion” on page 3-47.) Repeat this process for the co-pilot seat. ERIFICATION ETHOD Verify that results are within acceptable limits. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 244: Inspect Control Cables

    Use a magnifying glass if needed. If no internal corrosion is present, clean the outer surface with a clean, coarse-weave rag or fiber brush. After cleaning, apply LPS-3 Rust Inhibitor to the affected area. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 245 CONTROL CABLE. FIGURE 9-5 EXAMPLE OF CABLE SURFACE CORROSION. ERIFICATION ETHOD Ensure cables inspected fall within the acceptable conditions listed above. Otherwise follow the proce- dure listed for each type of unacceptable condition. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 246 9-10 FLIGHT CONTROLS / FLIGHT CONTROL SYSTEM GENERAL MAINTENANCE ELATED NFORMATION "Condition and 100-Hour Inspection—Forward Fuselage and Hull" on page 3-16 "Remove Roll Cables" on page 9-28 ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 247: Roll Controls

    A series of cables and pulleys are used to make this possible. Proper tensions and control cable health is required to achieve a predictable motion of the aircraft. 9.4.2 Roll Controls Diagram/Schematic FIGURE 9-6 FUSELAGE ROLL SYSTEM CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 248 Cables Tensiometer Location BL38 Clamshell Rig Pin Hole RH&LH Lower Roll Cable Turnbuckles FWD Pitch Sector Rig Pin Hole Secondary Stop Control Stick Rig Pin Hole FIGURE 9-7 FUSELAGE ROLL SYSTEM DETAILED VIEW ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 249: Inspection Instructions

    This section contains instructions to check roll cables for correct tensions. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Tensiometer and Operating Instructions 1 x DIA .250 Rig Pin CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 250 Install .250 in diameter rig pin through the center console and forward pitch sector. See Figure 9-9. FIGURE 9-9 PITCH SECTOR RIG PIN LOCATION ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 251 Use the tensiometer (upper cable thickness = 3/32 in, LH and RH fuselage cable thickness = 1/8 in) to measure roll cable tension at locations specified in, see Figure 9-12. Ensure they all are CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 252 Install cockpit floor boards. (See “Cockpit Floor Board Installation” on page 3-47.) ERIFICATION ETHOD Record results and check against requirement. If requirement is not met complete aileron rigging. (See “Rigging Roll Controls” on page 9-20.) ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 253 Digital level with 0.1° resolution and Alt Ref function, calibrated to manufacturers instructions A second person will be required during the inspection processes. Parts Required None Aircraft System and Number 14—Wing Consumables None CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 254 Have a helper move the control stick to lower the aileron trailing edge down against the stop (stop contact at outboard roll bellcrank should be heard). While holding very light (1-2 lb ) upward ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 255 In-line with the flap trailing edge within ±.02 inch _______________ Left Aileron ____° TED (15±2°) _________ ____° TEU (25±2°) Right Aileron ____° TED (15±2°) _________ ____° TEU (25±2°) ERIFICATION ETHOD Record results and check against requirement. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 256: Maintenance Instructions

    5 x DIA .1875 Rigging Pins 1 x DIA .250 Rigging Pins 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 aileron cable system is below. Part Number...
  • Page 257 Remove seatbelt reel cover, left hand and right hand baggage sidewalls, and baggage headliner. (See “Headliner Removal” on page 3-37.) If headliner cannot be removed without removal of overhead console, temporary removal is permitted. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 258 FIGURE 9-14 FWD PITCH SECTOR PIN LOCATIONS Install .1875 in diameter rig pin through the control stick rig pin hole. See Figure 9-15. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 259 Fold both aircraft wings and install 2X .1875 in diameter rig pins at both of the wing socket bell- crank. See Figure 9-16. RH SHOWN LH OPPOSITE INSERT PIN FROM SPAR POCKET SIDE OF BELLCRANK FIGURE 9-16 RIG PIN LOCATIONS CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 260 Adjust rod end lengths equally. Once adjusted, torque push tube jam nut to 60 inlbs. Torque through bolt and locking nut to 20 inlbs. See Figure 9-18. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 261 0+/-.02 in. Once adjusted, torque push tube jam nut to 60 in-lbs. Torque through bolt and locking nut to 20 in-lbs. Secure a digital protractor to the top surface of the aileron using double sided tape or equivalent. Set the protractor to zero. See Figure 9-19. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 262 Ensure ailerons maximum travel limits are set as specified. Trailing Edge Down: 15°+/-2° Trailing Edge Up: 25°+/-2° Check the LH and RH roll secondary stop. (See “Inspect Roll Rigging” on page 9-17. Step 4.) Remove FWD pitch sector rig pin. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 263 Install cockpit floor boards.(See “Cockpit Floor Board Installation” on page 3-47.) Install aileron access panel using retained fastening hardware. ERIFICATION ETHOD Conduct the Inspect Roll Rigging procedure (See “Inspect Roll Rigging” on page 9-17.) to verify proper rigging. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 264 Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 06—Flight Controls Consumables None See “Inspect Control Cables” on page 9-8. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 265 Control Stick Rig Pin Hole FIGURE 9-21 ROLL CONTROL SYSTEM OVERVIEW Disconnect the lower roll cable at the roll socket and at the turnbuckle at the stick. Ensure that cable is held while disconnecting the turnbuckle. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 266 There are two methods to remove the cable from the aircraft, either are acceptable: Remove the three pully pivot bolts Remove the two safety pins on each pully bracket. Remove the worn lower roll cable from the aircraft. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 267 Carefully slide the two parts of the old cable out of the aircraft. ERIFICATION ETHOD Damaged cables have been successfully removed and aircraft is ready for installation of replacement roll cable(s). CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 268 2x MS21256-1 (CLIP, LOCKING, TURNUCKLE) 12x MS25665-151 (PIN, COTTER, CRES, .063” x .500”) 1x ICA005909 (CONTROL CABLE, ROLL, FUSELAGE, UPR) 2x-4x MS21043-3 (LOCKING NUT, 10-32) Aircraft System and Number 06-Flight Controls Consumables None Install Lower Roll Cable: ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 269 Do not fully tension the cable system during this step. Ensure that when tightening the turnbuckle that the cable is held as NOTE to not wind the cable. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 270 Rig the roll system. (See “Rigging Roll Controls” on page 9-20.) ERIFICATION ETHOD The cables should be re-installed, and hardware torqued to the appropriate spec prior to rigging the system. Tensions should meet the requirements of the rigging section. ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 271: Roll Trim Tab

    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 installation of a different trim tab length on the aileron.

  • Page 272: Inspection Instructions

    Use the table as a guide to find the length of tab required. ERIFICATION ETHOD There should be only one roll trim tab on the aircraft. Roll tabs NOTE longer than 12 inches are not approved. If aircraft behavior indi- ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 273: Maintenance Instructions

    FLIGHT CONTROLS / ROLL TRIM TAB 9-37 cates that a longer tab is needed, contact ICON Aircraft for support as this may be an indication of some other problem. Trim Tab Length (in) Time to Roll 10° (sec) Time to Roll 20° (sec) ∞...

  • Page 274: Install Roll Trim Tab

    Task Specific Training Required Special Tools Required None Parts Required Roll trim tab stock, 90505, 24” 70006738424; 3M VHB Tape 5915WF White, 1/2 in, 16 mil Aircraft System and Number 06—Flight Controls Consumables ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 275 ERIFICATION ETHOD After the tape is fully cured, pull firmly on the component to ensure that it is bonded properly to the attaching surface. ELATED NFORMATION "Remove Roll Trim Tab" on page 9-37 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 276: Pitch Controls

    Input at the control stick in the FWD/AFT direction results in an output at the elevator control surface, controlling the pitch of the aircraft by pointing the nose up or down. 9.6.2 Pitch Control Diagram/Schematic FIGURE 9-28 PITCH CONTROL SYSTEM OVERVIEW ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 277 FLIGHT CONTROLS / PITCH CONTROLS 9-41 FIGURE 9-29 PITCH SECTOR, FWD DETAIL FIGURE 9-30 PITCH SECTOR, FWD DETAIL CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 278: Inspection Instructions

    Remove AFT bulkhead baggage panel. (See “Baggage Sidewall Panel Removal” on page 3-43.) Retain all fastening hardware. Install .250 in diameter rig pin through the center console and forward pitch sector. See “Rig Pin Location” on page 9-43. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 279 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 lb tension. Refer to the manufacturers’ calibration card to correctly read cable tension for the cable diameter. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 280: Inspect Pitch Rigging

    Refer to the manufacturers’ calibration card to correctly read cable tension for the cable diameter. ELATED NFORMATION "Condition and 100-Hour Inspection—Aft Fuselage and Empennage" on page 3-19 9.6.3.2 Inspect Pitch Rigging The following section contains the information required to perform the A5 maintenance inspection on the elevator. NFORMATION Type of Maintenance Line...
  • Page 281 (stop contact should be heard). Record level reading at maximum TEU travel. ESULT Reg. No. of Aircraft: Date of Test: Initials of Technician: Elevator ____° TED (21±2°) ____° TEU (19±1°) ERIFICATION ETHOD Record results and compare against requirements. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 282: Maintenance Instructions

    Task Specific Training Required Special Tools Required 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 is below. Number Name...
  • Page 283 Remove left hand and right hand forward and main cockpit floor boards.(See “Cockpit Floor Board Removal” on page 3-46.) Remove seat back and seat pan. (See “Seat Back Removal” on page 3-50.) (See “Seat Pan Removal” on page 3-52.) Retain all fastening hardware. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 284 (cable thickness = 1/8 in). Adjust turnbuckles as required to set cable tension to 20 – 35 lbs. Refer to Figure 9-34. Operate tensiometer per its manufacturer’s instructions. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 285 12-6.)(See “Horizontal Tail Tip Pin” on page 12-19.) Ensure the rig pin in the FWD pitch sector is still installed. If installed, remove the hardware which secures the elevator push rod to the elevator control horn. See Figure 9-36. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 286 Using the digital protractor, check the maximum upward and downward deflection of the elevator. If required, adjust the elevator push tube rod end as necessary to achieve the following: 19° ± 1° upward deflection 21° ± 2° downward deflection ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 287 Install left hand and right hand forward and main cockpit floor boards. (See “Cockpit Floor Board Installation” on page 3-47.) ERIFICATION ETHOD Conduct the Check Elevator Rigging Procedure to verify proper rigging. (See “Inspect Pitch Rigging” on page 9-44.) CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 288 "Horizontal Tail Installation" on page 12-13 "Center Console Bucket Removal" on page 8-5 "Center Console Bucket Installation" on page 8-8 "Throttle Handle and Bezel Removal" on page 8-10 "Throttle Handle and Bezel Installation" on page 8-13 ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 289: Pitch Trim Actuator

    PITCH TRIM ACTUATOR ASSEMBLY 9.7.3 Maintenance Instructions 9.7.3.1 Remove Pitch Trim Actuator The pitch trim actuator removal procedure is needed as part of the process of replacing the actuator. NFORMATION Type of Maintenance CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 290 If trim actuator needs to be replaced, remove the actuator from the mounting bracket by removing the four mounting screws, washers, and nuts. ERIFICATION ETHOD This procedure is successful when the trim actuator and mounting bracket are successfully removed from the aircraft. ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 291: Install Pitch Trim Actuator

    Aircraft System and Number 06—Flight Controls Consumables ® Tef-Gel NSTRUCTIONS Mount new ICA006821 trim actuator to the pitch trim bracket by installing the four mounting cross head screws, washers, and nuts previously removed as shown. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 292 If pushrod needs to be replaced for wear, assemble the pushrod (ICA007117), helical coil (1191-4CN500), jam nut (AN316C4R), and fork (ICA008302) as shown. Install push rod assembly on actuator by installing clevis pin (MS20392-1R11), washer (NAS1149CN432R), and cotter pin (MS24665-151) as shown. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 293 (right side shown, repeat for left side). Torque screws to 26 in-lb ® Install elevator center hinge bolt and washer as shown. Apply Tef-Gel prior to installing and torque to 26 in-lb CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 294 Connect trim tab pushrod to the trim tab, as shown, by installing the pin (MS20392-1R11), washer (NAS1149CN432R), and cotter pin (MS24665-151). Do not bend the cotter pin until rigging in next step is complete. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 295 Install the horizontal tail tips. ERIFICATION ETHOD Check and make adjustments as needed to the pitch trim rigging. (See “Inspect Pitch Trim Tab Rigging” on page 9-61.) ELATED NFORMATION "Inspect Pitch Trim Tab Rigging" on page 9-61 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 296: Pitch Trim Tab

    This trim tab can only be controlled from the top of the LH control stick. The trim tab is adjusted to relieve the pilot from having to exert a constant pressure on the pitch controls. 9.8.2 Pitch Trim Tab Diagram/Schematic FIGURE 9-40 PITCH TRIM TAB AND VERTICAL TAIL ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 297: Inspection Instructions

    Inspect Pitch Trim Tab Rigging The following section contains the information required to perform an inspection of the pitch trim tab rigging. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 298 60 in-lb Turn off the master switch. Remove inclinometer and any tape used to secure it to the elevator trailing edge. ESULT Reg. No. of Aircraft Date of Test: Initials of Technician: ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 299: Measure Pitch Trim Tab Wear

    Operate the trim tab until its trailing edge aligns with that of the elevator. Zero the inclinometer. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 300 Record results and check trim tab control horn hole is within these limits. If tolerance is larger than specified, repair is required. Contact ICON for repair. • Maximum trim tab control horn hole diameter = Ø.160 inch...

  • Page 301: Flap Controls

    9.9.2 Flap Controls Diagram/Schematic FIGURE 9-42 FLAP CONTROLS OVERVIEW 9.9.3 Inspection Instructions 9.9.3.1 Inspect Flap Rigging Perform ground rigging inspection check on A5 flaps. NFORMATION Type of Maintenance Line Level of Certification CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 302 Select 30° flap position. Again, pull up on flap trailing edge with a light pressure to remove play. Record the level reading in table below. Repeat steps 1-8 on other side. ESULT Reg. No. of Aircraft: Date of Test: Initials of Technician: ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 303 Special Tools Required 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 flap cable system is below. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 304 .328X.016, PSVT NAS1149C0563R WASHER, FLAT, CRES, 2 EA .312X.63, PSVT NAS1149C1232R WASHER, FLAT, CRES, 8 EA .750X.032, PSVT NAS1149C0532R WASHER, FLAT, CRES, 1 EA .312X.032, PSVT MET000663-A FLAP ACTUATOR, SUBASSY, 1 EA Serialized ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 305 Push cable position can be changed by loosening all jam nuts and running the bellcrank rod end and cable socket in or out equally. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 306 Figure 9-44. Refer to Figure 9-43 for actuator location. Outboard Pushtube Inboard Pushtube Rod End B Outboard Flap Pin Gas Spring Rod End C Rod End A Up Stop FIGURE 9-44 WING FLAP SYSTEM OVERVIEW ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 307: Maintenance Instructions

    "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Inspect Flap Rigging" on page 9-65 "Install Flap Actuator" on page 9-74 9.9.4 Maintenance Instructions 9.9.4.1 Remove Flap Actuator Use these instructions to remove the flap actuator. NFORMATION Type of Maintenance Line CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 308 Set actuator rod end position as shown. Be sure that the rod end is clocked in a way so that it will sit in the flap bellcrank properly. Torque jam nut to 50-70 in-lbs. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 309 Disconnect the flap actuator from the flap bellcrank by removing the AN4C10A bolt that fastens them together. Retain hardware for reinstallation. (See “Removal and Installation of Inspection Panels and Fairings” on page 3-34.) CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 310: Remove Flap Actuator

    "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Install Flap Actuator" on page 9-74 9.9.4.2 Install Flap Actuator These instructions should be used to install the flap actuator. NFORMATION Type of Maintenance ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 311 Set actuator limit switches. (See “Rigging Flap Controls” on page 9-67.) Reinstall the bulkhead panel. (See “Removal and Installation of Inspection Panels and Fairings” on page 3-34.) ERIFICATION ETHOD Verify actuator limit switches against Flaps Rigging. (See “Inspect Flap Rigging” on page 9-65.) CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 312: Remove Flap Gas Strut

    Remove the ball retaining clip from the rod end of the strut. Pull the rod end socket off the ball-end stud. Be aware that there will be some preload on the strut if its cylinder is still holding pressure. ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 313: Install Flap Gas Strut

    243™ on the threads of the ball stud. Torque the ball stud nut to 50 in-lb Ensure that there are two NAS1149C0463R washers on the threaded stud that attaches the cylinder end of the strut to the structure, prior to strut installation.See Figure 9-49. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 314 Visually inspect the system for proper function and security. ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Inspect Flap Rigging" on page 9-65 ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 315: Yaw Controls

    Rudder Return Spring Spring Primary Stops Primary Stops AFT Yaw Cable AFT Yaw Cable Tensiometer Location Tensiometer Location Fwd Yaw Cable Fwd Yaw Cable Tensiometer Location Tensiometer Location FIGURE 9-50 YAW CONTROLS OVERVIEW CHANGE C3 ICON A5 / MAINTENANCE MANUAL...

  • Page 316: Inspection Instructions

    Remove the Center Console Bucket. (See “Center Console Bucket Removal” on page 8-5.) Retain all fastening hardware. Install two .1875 in diameter rig pins, one in FWD Yaw Bellcrank and one in the Water Rudder Bell- crank. See Figure 9-51. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 317 1/8 in) to measure rudder cable tension. Refer to Figure 9-52. Ensure they all are within 18-22 lb of tension. Refer to the manufacturers’ calibration card to correctly read cable tension for the cable diameter. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 318 Install AFT Bulkhead Baggage Panel using retained hardware during removal. (See “Baggage Sidewall Panel Installation” on page 3-45.) ERIFICATION ETHOD Record results and check against requirement. If requirement is not met complete rudder rigging. (See “Inspect Yaw Rigging” on page 9-85.) ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 319 Use task to inspect the rigging of the rudder pedals to the rudder rails. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required None Special Tools Required Protractor or inclinometer Parts Required None Aircraft System and Number 06—Flight Controls Consumables None CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 320 ERIFICATION ETHOD The measurement should be 90°± 1°. If not within this specification, refer to the re-rigging process/installation for instructions on how to rig correctly. (See “Re-Rigging Rudder Pedals” on page 9-103.) ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 321: Inspect Yaw Rigging

    FLIGHT CONTROLS / YAW CONTROLS 9-85 ELATED NFORMATION "Re-Rigging Rudder Pedals" on page 9-103 9.10.3.3 Inspect Yaw Rigging The following section contains the information required to perform the A5 maintenance inspection on the rudder. NFORMATION Type of Maintenance Line Level of Certification...
  • Page 322 (1-2 lbf) pressure towards neutral on the rudder trailing edge to remove play. Maximum travel limits are set as specified. See Figure 9-54. Trailing Edge Left: 11°+/-1° Trailing Edge Right: 14°+/-1° ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 323: Maintenance Instructions

    "Adjust Yaw Rigging" on page 9-100 9.10.4 Maintenance Instructions 9.10.4.1 Rigging Yaw Controls Use the following procedure for rudder rigging. NFORMATION Type of Maintenance Line Level of Certification A&P Task Specific Training Required CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 324 FLIGHT CONTROLS / YAW CONTROLS Special Tools Required 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 rudder cable system is below. Number Name...
  • Page 325 BEARING, BALL, AFR AFB, EX LD, 1.06X1.50X.281 NAS428H3-7 BOLT, MACH-CRWND HEX HD, ADJUSTING, CRES, 10-32X.875 NAS75C4-00 BUSHING , PLAIN, CRES, .250X.375X.188 NAS77C3-01 BUSHING, FLNGD, UNLINED, CRES, .190X.150 VH-112-S16 RETAINING RING, PLAIN, LIGHT DUTY, 316SS, 1.25X.025 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 326 Inspect all components within the rudder circuit for excessive wear. Any components that show excessive wear or damage must be replaced with new components. Disconnect rudder return spring by removing the FWD bolt. Retain hardware. See Figure 9-55. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 327 Ensure rig pin extends the entire width of the keel, through both NOTE holes in the keel. Water Rudder Bellcrank Rig Pin Location Rig Pin Location Forward Yaw Bellcrank FIGURE 9-56 FWD YAW BELLCRANK AND WATER RUDDER RIG PIN LOCATIONS CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 328 Ensure that no more than 3 cable terminal threads are exposed after turnbuckle adjust- ments Ensure that water rudder remains centered 0° ± .5° relative to the BL_0 plane after rigging is completed ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 329 AFT YAW CIRCUIT TENSIONING ® Install the forward end of centering spring 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. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 330 4 total on aft section of Yaw System – 2X ICA012239 (Rod End), 2X MS21256-2 (Wire Terminal) 4 total on mid section of Yaw System – 4X MS21256-1 8 total on Rudder Pedal Control Cables – 8X MS21256-2 ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 331 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 of the tail section under the rudder. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 332 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 rod and adjusting the rod end. See Figure 9-62. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 333 FLIGHT CONTROLS / YAW CONTROLS 9-97 Bolt Push Rod Water Rudder Bellcrank FIGURE 9-62 RUDDER PUSH TUBE ADJUSTMENT Repeat step 17 for the LH pedal. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 334 ) pressure towards neutral on the rudder trailing edge to remove play. Adjust primary stops to ensure rudder maximum travel limits are set as specified. See Figure 9-64. Trailing Edge Left: 11°+/-1° Trailing Edge Right: 14°+/-1° ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 335 Install Center Console Bucket and Throttle Bezel. (See “Center Console Bucket Installation” on page 8-8.)(See “Throttle Handle and Bezel Installation” on page 8-13.) ERIFICATION ETHOD Conduct the Check Rudder Rigging procedure (See “Inspect Yaw Rigging” on page 9-85.) to verify proper rigging. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 336 Adjust the rigging to prevent slight yaw tendency. NFORMATION Type of Maintenance Line Level of Certification A&P Task Specific Training Required Special Tools Required None Parts Required None Aircraft System 06—Flight Controls Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 337: Adjust Rudder Pedal Rigging

    Use this task to adjust the rudder pedal rigging. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Digital level with 0.1° resolution and Alt Ref function, calibrated to manufacturer’s instructions. Parts Required CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 338 If the angle between the arms and rails can’t be set to 90° ± 1° by adjusting the turnbuckles, the control cables need to be re-rigged. Follow the process for re-rigging. (See “Re-Rigging Rudder Pedals” on page 9-103.) ICON A5 / MAINTENANCE MANUAL CHANGE C3...

  • Page 339: Re-Rigging Rudder Pedals

    ICA009510 Control Cable MS51844-23 Sleeves AN100C-4 Thimbles MS24665-151 Cotter Pins Aircraft System and Number 06—Flight Controls Consumables None NSTRUCTIONS Remove existing rudder pedal cables. Cut cable just after the MS51844-23 swage sleeve and remove. CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 340 Remove slack from rudder pedal cables while maintaining 90° ± 1° at the rudder pedal arms. Mark the rudder cables. Uninstall cable from the forward rudder rail mount. Ensure the mark created in Step 4 is in the correct location. Swage MS51844-23 sleeve. Install the rudder pedal cables. ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 341 "Adjust Rudder Pedal Rigging" on page 9-101 "Re-Rigging Rudder Pedals" on page 9-103 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Inspect Yaw Rigging" on page 9-85 "Check Water Rudder Rigging" on page 11-12 CHANGE C3 ICON A5 / MAINTENANCE MANUAL...
  • Page 342 9-106 FLIGHT CONTROLS / YAW CONTROLS ICON A5 / MAINTENANCE MANUAL CHANGE C3...
  • Page 343 Clear Fuel Tank Vent Line........... . 10-35 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 344: Fuel System Description

    Does not include fuel flow rate sensing, transmitting and/or indicating, which are covered in the Instruments system. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 345: Troubleshooting

    Turn master switch on. The voltage between Pin 1 and Pin 3 at the aircraft harness gauge connector should be 12v. If it is not, the sensor may be faulty. Turn master switch off. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 346: Fuel Pressure Diagnostic

    Use Table 10-1 to diagnose the fuel system when the pressure is outside the normal limits (40.5-46.5 psi) or when FUEL PRESS illuminates on the annunciator panel. See “Annunciator Panel Diagnostic” on page 13-9. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 347 See the “Maintenance Manual Line 912i ® Series” fuel system section from Rotax Plugged fuel tank vent line. Clear fuel tank vent line. (See “Clear Fuel Tank Vent Line” on page 10-35.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 348 Line 912i Series” from Rotax Blockage between regulator Inspect flow between fuel pressure and fuel tank. regulator and fuel tank. Check for kinks. Refer to the “Maintenance Manual Line ® 912i Series” from Rotax ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 349: Fuel System General Maintenance

    Close and secure the fuel cap onto the fuel cap fitting. The latch on the fuel cap should swing downward when properly aligned. ERIFICATION ETHOD Fuel tank sump is visually clear of water or debris. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 350: Pump Usable Fuel From Fuel Tank

    Remove the top engine cowl. (See “Remove Engine Cowlings” on page 16-13.) Use an 11/16 wrench to disconnect the fuel supply hose at the fuel rail on the engine’s left-forward corner (circled in Figure 10-1). Catch any fuel that drips out. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 351 Install the top engine cow. (See “Install Engine Cowlings” on page 16-16.) ERIFICATION ETHOD Verify that the fuel line is secured without any leaks. Verify that the Top Cowl is replaced and secured into position. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 352: Clear Filler Neck

    After check and confirmation filler tube is clear, replace fuel cap. ERIFICATION ETHOD Fuel flows freely into the fuel tank through the filler neck. ELATED NFORMATION "Condition and 100-Hour Inspection—Fuel Systems" on page 3-13 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 353: Fuel Bladder (My17 Only)

    With a 7/16 wrench, disconnect the T9028 ring terminal from the fuel level sensor access plate. With a 3/8 wrench, disconnect the ground strap at the fuel vent line from the tank’s fuel filler flange. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 354: Install Fuel Bladder (My17 Only)

    "Rigging Pitch Controls" on page 9-46 10.4.1.2 Install Fuel Bladder (MY17 Only) Use the following procedure to install the fuel bladder. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 355 Torque to 40 in-lbs Fill the bladder with fuel and check for leaks. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 356 NFORMATION "Baggage Sidewall Panel Installation" on page 3-45 "Seat Back Installation" on page 3-51 "Bilge Pump Installation (MY17)" on page 6-44 "Rigging Yaw Controls" on page 9-87 "Rigging Pitch Controls" on page 9-46 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 357: Fuel Tank (My18+)

    Remove seat backs. (See “Seat Back Removal” on page 3-50.) Pump all fuel from tank. (See “Pump Usable Fuel From Fuel Tank” on page 10-8.) Disconnect the optical switch connector from D9038P. (See Figure 10-2.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 358 Use a 7/16 wrench to remove bolt, washer, and T9028 terminal on fuel level sensor plate. (See Figure 10-2.) Remove three cable ties securing T9028 terminal wire harness. Remove #6-32 screw securing the T9027 terminal on the fuel cap adapter. (See Figure 10-3.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 359: Fuel System

    Disconnect fuel sump hose by prying off its clamp and pulling the hose off the barb. (See Figure 10-3.) Remove fuel filler hose completely. Remove self-locking nut from both T-bolt shanks located at FWD end of fuel tank. (See Figure 10-4. Detail A.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 360 Remove two bolts and washers securing the fuel tank straps to the aft end of fuel tank. (See Figure 10-4. Detail D.) Remove both fuel tank straps. Lift fuel tank subassembly out of the aircraft. ERIFICATION ETHOD Task is complete when the fuel tank has been removed from the aircraft. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 361 15300010 (CLAMP, HOSE, CRIMP, CRES, OETIKER, 0.344) TY528MX (CABLE TIE, NYLON 6-6, 50LB, 14.2, TY-RAP) TY24MX (CABLE TIE, NYLON 6-6, 30LB, 5.50, TY-RAP) Aircraft System and Number 07—Fuel System Consumables ® Tef-Gel LOCTITE 243 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 362 10-20 FUEL SYSTEM / FUEL TANK (MY18+) FIGURE 10-5 FUEL TANK INSTALLATION NSTRUCTIONS Ensure isolation strips are properly aligned on fuel tank support structure. (See Figure 10-6.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 363 Route fuel sump hose through bottom end of fuel filler neck and connect the fuel sump hose to sump hose adapter using a new CLAMP, HOSE, CRIMP (Oetiker clamp). Tighten with ear-clamp crimpers. (See Figure 10-7.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 364 Attach the top end of the filler neck onto the fuel cap adapter. (See Figure 10-8.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 365 Do not over tension cable tie and create a blockage or kink in fuel CAUTION vent hose. Connect the optical switch connector to D9038P form fuselage wire harness.(See Figure 10-7.) Connect the fuel level sensor connector to D9038P from fuselage wire harness.(See Figure 10-7.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 366 The procedure is complete when the fuel tank is installed with no leak. ELATED NFORMATION "Headliner Installation" on page 3-38 "Baggage Floor Installation" on page 3-42 "Baggage Sidewall Panel Installation" on page 3-45 "Seat Back Installation" on page 3-51 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 367: Coarse Fuel Filter

    The coarse fuel filter is one of two filters in the fuel supply line. The same filter, FX375-M, is used in both the MY17 and MY18+ ICON A5 and is located above the fuel bladder/tank. Unlike the fine fuel filter, the coarse fuel filter can be cleaned and does not need to be replaced unless it is damaged.
  • Page 368 Make a note of fuel flow direction through the filter. Using an 11/16 wrench, loosen the AN-6 fitting while securing the filter from rotation. Rotate the AN-6 connection fitting until completely free. (See Figure 10-10.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 369 Tighten the AN-6 (9/16-18 thread) fittings on the inlet and outlet sides of the filter. Torque fittings to 110-130 in-lbs. Torque the 10-32 nut on the click bond stud to 40 in-lbs. Turn on fuel valve, turn on master power, turn key to A position, and check for leaks. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 370: Clean Coarse Fuel Filter (My18+)

    Use a rag or shallow container to catch any fuel that leaks from the fuel lines or the filter itself. Make note of fuel filter orientation. Using an 11/16 wrench, rotate the AN-6 fitting while securing the filter from rotation. Rotate the AN-6 connection fitting until completely free. (See Figure 10-11.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 371 Install baggage floor. (See “Baggage Floor Installation” on page 3-42.) Install seat backs if previously removed. (See “Seat Back Installation” on page 3-51.) ERIFICATION ETHOD Complete engine test run and check for leaks. (See “Engine Test Run” on page 16-7.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...

  • Page 372: Fine Fuel Filter

    Use a 13/16 wrench to hold the union fitting at the fuel pressure relief block while loosening the adjacent -6 AN B-nut with an 11/16 wrench shown in Figure 10-12. Catch the fuel as it leaks from the joint. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 373 Wipe away or clean any fuel which may have dripped inside the cabin. At the fuel filter outlet, loosen the -6 AN B-nut with an 11/16 wrench while holding the 12mm adapter fitting with a 3/4 wrench. See Figure 10-13. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 374 -6 JIC X 12MM -6 AN B-NUT FIGURE 10-13 FINE FUEL FILTER AND ATTACHED PLUMBING Use two 3/4 wrenches to remove the inlet adapter fitting from the old filter. Discard the 14mm washer. See Figure 10-14. ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 375: Install Fine Fuel Filter

    10.7.1.2 Install Fine Fuel Filter Use the following instruction to install the fine fuel filter. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 376 Complete engine test run and check for leaks. (See “Engine Test Run” on page 16-7.) ELATED NFORMATION "Remove Fine Fuel Filter" on page 10-30 "Headliner Installation" on page 3-38 "Engine Test Run" on page 16-7 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 377: Fuel Tank Vent Line

    To prevent positive pressure, do not cap or seal the fuel cap opening in any way. ERIFICATION ETHOD Ensure air is exiting freely from the vent in the wing. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 378 10-36 FUEL SYSTEM / FUEL TANK VENT LINE ELATED NFORMATION "Condition and 100-Hour Inspection—Fuel Systems" on page 3-13 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 379: Fuselage And Vertical Tail

    Installation of Water Rudder Cable ..........11-17 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 380: Fuselage And Vertical Tail Description

    Includes: skins, bulkheads, ribs, fuselage-to-wing fillets, door/canopy jambs, as well as integral or mounted aircraft hand-holds, tie downs and mooring cleats, mid, forward, and aft wing pin recepta- cles, and firewall structure with thermal protection material(s) as required. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 381: Fuselage And Vertical Tail General Maintenance

    With the canopy raised and supported, use a wrench to remove the eight AN4C6A bolts and 91950A029 washers that secure the ICA005811 canopy hinge weldment to the canopy frame. The bolts are threaded into blind nutplates. See Figure 11-1. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 382: Canopy Installation

    "Right Instrument Panel Top Panel Installation" on page 8-18 11.2.2 Canopy Installation Use the following procedure to install the canopy. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 383 Install left and right instrument panel top panels. (See “Left Instrument Panel Top Panel Installa- tion” on page 8-21.)(See “Right Instrument Panel Top Panel Installation” on page 8-18.) ERIFICATION ETHOD Open and close the canopy several times, ensuring correct operation and fitment. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 384 "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 8-21 "Right Instrument Panel Top Panel Installation" on page 8-18 ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 385: Seawings

    Inspect the four pins on the Seawings™, verifying that all are securely bonded. Before installing the original or replacement tip, inspect its condition, verifying no cracks or other structural issues and that the four attachment bushings are in good condition and securely bonded in place. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 386: Repair Of Seawings™ Tip Attach Pins And Bushings

    Aircraft System and Number 08—Fuselage and Vertical Tail Consumables Isopropyl Alcohol Plexus MA830 Adhesive NSTRUCTIONS Remove the Seawings™ tip using the removal procedure. (See “Seawings™ Platform Tip Removal and Installation” on page 11-7.) ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 387 Remove the protective tape and check the bond lines for signs of good adhesive squeeze out and bond integrity. Install the Seawings™ tip. (See “Seawings™ Platform Tip Removal and Installation” on page 11-7.) CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 388 11-10 FUSELAGE AND VERTICAL TAIL / SEAWINGS™ ERIFICATION ETHOD Procedure is complete when Seawings™ tip has been attached. ELATED NFORMATION "Seawings™ Platform Tip Removal and Installation" on page 11-7 ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 389: Water Rudder

    While observing the actuator area, check for freedom of motion of all parts. The return spring should maintain tension on the cable throughout the entire motion. There should be no slack in the cable at any time. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 390: Check Water Rudder Rigging

    "Removal of Water Rudder Cable" on page 11-15 "Installation of Water Rudder Cable" on page 11-17 11.4.1.2 Check Water Rudder Rigging The following section contains the information required to perform the A5 maintenance inspection on the water rudder. NFORMATION Type of Maintenance...
  • Page 391 ESULT Reg. No. of Aircraft: Date of Test: Initials of Technician: Water Rudder ____° TEL (40±5°) ____° Neutral (0±.5°) ____° TER (40±5°) ERIFICATION ETHOD Record results and check against requirements. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...

  • Page 392: Maintenance Instructions

    Assemble water rudder into flange on aircraft using 91950A029 on the outside, and bolting ® through the bushing ICA008934 and bolt with 97851A104 using LOCTITE 243™ and torque to 1/4 turn past sharp rise in torque. ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 393: Removal Of Water Rudder Cable

    NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Cable Cutter Parts Required None Aircraft System and Number 08—Fuselage and Vertical Tail Consumables None CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 394 Remove the cable from the puck by disengaging the swaged bull from the notch in the puck. Discard the old cable and clean all parts. ERIFICATION ETHOD Confirm old cables are removed and parts are clean. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 395 Slide the puck into the water rudder. The puck is properly oriented when the two mating screw holes align and the swaged ball faces aircraft aft when rudder is in the retracted position. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 396 Repeat this for the extension end of the cable and its turn- buckle. Find the swage location mark on the retraction cable end. Position the cable so that the center mark is located at the center point of the thimble of the retraction turnbuckle ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 397 (See “Installation of Water Rudder Cable” on page 11-17.)(See “Water Rudder Actuator and Cables” on page 11-11.) ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Check Water Rudder Rigging" on page 11-12 "Water Rudder Actuator and Cables" on page 11-11 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 398 11-20 FUSELAGE AND VERTICAL TAIL / WATER RUDDER ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 399: Horizontal Tail

    Horizontal Tail Tip Pin............12-20 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 400 12-2 HORIZONTAL TAIL / HORIZONTAL TAIL DESCRIPTION 12.1 Horizontal Tail Description Horizontal tail includes the structure of the elevator control surface. Includes: skins, ribs, webs, hinges and counterbalance. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 401 Install horizontal tail tips and repeat play steps 2 and 3. Examine the tips and tail for excessive play. Tips should feel secure without relative motion to the tail. ERIFICATION ETHOD Confirm results are within acceptable limits. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 402 Use the following to inspect the Horizontal Tail Empennage skin for damage/delaminations. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 09—Horizontal Tail Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 403 Remove horizontal tail tip access panels. Using a flashlight, visually inspect bond lines and struc- ture for damage and cracks. ERIFICATION ETHOD Tap testing described will verify whether there is damage or delaminations. ELATED NFORMATION "Manual Tap Test" on page 3-55 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 404 Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 09—Horizontal Tail Consumables None NSTRUCTIONS Remove horizontal tail tip access panel. Keep screws for reinstallation. (See Figure 12-2.) ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 405 HORIZONTAL TAIL / HORIZONTAL TAIL GENERAL MAINTENANCE 12-7 FIGURE 12-2 REMOVE HORIZONTAL TAIL TIP ACCESS PANEL (LH SHOWN, RH OPPOSITE) Remove the 4 screws, washers, and nuts securing limit switches. Set aside for installation. (See Figure 12-3.) CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 406 12-8 HORIZONTAL TAIL / HORIZONTAL TAIL GENERAL MAINTENANCE FIGURE 12-3 REMOVE SCREWS SECURING SWITCHES Unplug and remove limit switches from wiring harness. (See Figure 12-4.) ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 407 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Install Horizontal Tail Tip Lock Switches" on page 12-16 12.3.1.2 Air Rudder Removal Use these instructions to remove the air rudder. NFORMATION Type of Maintenance CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 408 "Horizontal Tail Removal" on page 12-11 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 12.3.1.3 Elevator Pushrod Removal Use these instructions to remove the elevator pushrod. NFORMATION Type of Maintenance ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 409 Once the elevator pushrod is completely detached from the aircraft, this task is complete. ELATED NFORMATION "Horizontal Tail Removal" on page 12-11 12.3.1.4 Horizontal Tail Removal Instructions for removing the Horizontal Tail. NFORMATION Type of Maintenance Line CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 410 Disconnect the multi-pin wire connector and coaxial cable connectors at the vertical tail/hori- zontal tail joint. Remove the horizontal tail. ERIFICATION ETHOD Once horizontal tail is completely detached from the aircraft, this task is complete. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 411 Lower the horizontal tail into position so that the composite fitting projecting down from the hori- zontal tail likes flush with the vertical tail spar. Use care to avoid pinching the electrical cables; feed slack in cables through hole in top vertical tail rib. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 412 Use these instructions to install the elevator pushrod after the horizontal tail has been installed. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 413 12.3.1.7 Air Rudder Installation Use thee instructions to install the air rudder after the elevator pushrod had been installed. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 414 12.3.1.8 Install Horizontal Tail Tip Lock Switches Use the following procedure to install the two horizontal tail tip lock switches. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 415 Rotate the lock handle to the “Locked” position. Verify the wing tip lock switch is engaged. The switch will click when it is fully engaged. Verify at the annunciator panel that “LOCK WING/TAIL” light is out. See Figure 12-5. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 416 Once the two limit switches are installed and functional, this task is complete. ELATED NFORMATION "Horizontal Tail Removal" on page 12-11 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Remove Horizontal Tail Tip Lock Switches" on page 12-6 ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 417 ERIFICATION ETHOD Record results and check that wear is within these limits. Replace if outside limit (See “Horizontal Tail Tip Pin” on page 12-20.) CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 418 1/8 in open-end wrench. Remove a pin using a wrench to rotate the pin as one would a bolt or stud. Ensure that the wrench fits securely and turn the pin carefully to avoid rounding off the flats. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 419 After pin replacement, install the tip on the horizontal tail and verify correct fit and that the secure wing/tail light on the pilot’s annunciator panel indicates correctly. ELATED NFORMATION "Measure Horizontal Tail Tip Anti Rotation Pin Wear" on page 12-19 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 420 12-22 HORIZONTAL TAIL / HORIZONTAL TAIL TIP PIN ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 421: Instruments (And Avionics)

    ELT Remote Control Panel Battery Replacement ......13-50 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 422 Check Wing Connections........... 13-86 ICON A5 / MAINTENANCE MANUAL...
  • Page 423 13.1 Instruments and Avionics Description ICON’s A5 aircraft components and avionics include all sensors, indicating instruments, flight data recorder, navigation and communication units. This also includes the pitch trim indicator, hour meter, RF antennae and cabling, communication equipment controls, headset jacks, intercom switches and auxiliary microphone input jack.
  • Page 424 Information in this section should be used to verify that markings shown in solid lines are legible. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 10—Instruments (and Avionics) Consumables None NSTRUCTIONS Center Console ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 425 INSTRUMENTS (AND AVIONICS) / TROUBLESHOOTING 13-5 Left Crossbeam CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 426 13-6 INSTRUMENTS (AND AVIONICS) / TROUBLESHOOTING Overhead Console Parking Brake ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 427 INSTRUMENTS (AND AVIONICS) / TROUBLESHOOTING 13-7 Center Armrest Bucket ERIFICATION ETHOD Verify all lines and text are visible and legible. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 428 14 CFR Part 43, Appendix F. ELATED NFORMATION "Interval Maintenance—Calendar Intervals" on page 3-5 13.2.3 Magnetic Direction Indicator Calibration The following directions should be used to calibrate the magnetic direction indicator of the A5. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot...
  • Page 429 LANE A minor fault. Retrieve and review ECU data. See LANE B minor fault. “ECU Troubleshooting” on page LANE A & B minor faults. 16-9. LAND AIRCRAFT LANE A or B major fault. ENGINE CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 430 (FP < 38.5) Excessively See FUEL PRESS light trouble shooting section for FUEL PRESS High fuel high fuel pressure possible cause and remedy. pressure (FP > 50.0) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 431 Sport (912 iS 2) Heavy Maintenance Manual” alternator replacement. ALTERNATOR Low voltage on main bus (less than Diagnose issue using wiring 13 VDC) schematics. See “Electrical System Wiring Diagrams” on page 6-4. ENGINE CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 432 6-32. Battery not charging with engine See “Battery Diagnostic” on page running. 6-32. Master Switch is OFF. Turn Master Switch ON. 30 amp circuit breaker pulled. Reset 30 amp circuit breaker. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 433 Test battery and replace if necessary. See “Battery Removal and BATTERY Installation” on page 6-37. Battery not charging with engine See “Battery Diagnostic” on page running. 6-32. See “Electrical System Wiring ALTERNATOR Diagrams” on page 6-4. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 434 Tail Tip Lock Switches” on page 12-6. See “Install Horizontal Tail Tip Lock Switches” on page 12-16. PURGE BILGE More than 1 gallon in bilge. Run bilge pump. See “Check Bilge Pump Function” on page 6-42. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 435 Use this procedure to replace any indicated component mounted in the overhead console. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 10—Instruments (and Avionics) Consumables CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 436 SJTC02000 Terminal Block, Mounting Track W23-X1A1G-30 Circuit Breaker, 30A ICA006179 Horn, Stall Warning E-04-5 Switch, Remote, ELT Test/Reset E-04-7 Horn, ELT Audio Alert E-04-10-3 Cable, Audio Alert, ELT ICA010402 Potentiometer, 10K Map Light ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 437 Watch out for pinch points at the screw bosses to avoid damaging wiring. Torque each screw to 13 in-lb Connect the D9078P and D9079J wire harness connectors and the ELT phone connector. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 438 Use this procedure to replace any indicated fuse mounted in the overhead console shown in Figure 13-1. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 10—Instruments (and Avionics) Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 439 Figure 13-1. The fuse should match the blown fuse in both color and amp rating. Discard the blown fuse. Insert the spare fuse firmly into the appropriate location identified in Step 1. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 440 13-20 INSTRUMENTS (AND AVIONICS) / INSTRUMENTS AND AVIONICS GENERAL MAINTENANCE FIGURE 13-2 FUSE PANEL ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 441 “System Wiring Diagram, Exterior Lights” on page 6-12 Strobe controller “System Wiring Diagram, Exterior Lights” on page 6-12 WATER RUDR Water Rudder Actuator “Water Rudder” on page 11-11 “System Wiring Diagram, Water Rudder” on page 6-29 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 442 Contactor “System Wiring Diagram, Engine Interface” on page 6-8 HEAT Cabin Heat “Cabin Heater” on page 7-3 “System Wiring Diagram, Heater” on page 6-17 Solenoid valve “System Wiring Diagram, Heater” on page 6-17 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 443 Lights” on page 6-12 RH taxi-landing “System Wiring Diagram, Exterior Lights” on page 6-12 BILGE Bilge Pump Bilge Pump “Check Bilge Pump Function” on page 6-42 “System Wiring Diagram, Bilge” on page 6-5 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 444 Main gear up relay “System Wiring Diagram, Landing Gear” on page 6-22 Main gear down relay “System Wiring Diagram, Landing Gear” on page 6-22 Nose gear up relay “System Wiring Diagram, Landing Gear” on page 6-22 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 445 Press button and hold for 5 seconds. During this time, an LED next to the switch will flash at a 2 Hz rate NOTE and flashes a GREEN indicator. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 446 ICA010989 (INDICATOR, ALTIMETER, SINGLE PTR, 3.12DIA) ICA010990 (INDICATOR, FUEL QTY, 2.25 DIA) ICA010992 (INDICATOR, OIL TEMP, 1.25 DIA) ICA010993 (INDICATOR, OIL PRESSURE, 1.25 DIA) ICA010994 (INDICATOR, COOLANT TEMP, 1.25 DIA) ICA010991 (INDICATOR, TACHOMETER, 2.25 DIA) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 447 13.3.5 Multiple Systems Controller (MSC) Replacement Use the following procedure to replace the multiple systems controller (MSC). NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 448 Reinstall the DAC and its electrical connections. Install the Right Instrument Panel Top Panel.(See “Right Instrument Panel Top Panel Installation” on page 8-18.) ERIFICATION ETHOD Power up and check all avionics and electrical systems for proper function. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 449 “Pitot Static Leak Check Operation” on page 13-75.) NSTRUCTIONS Remove cluster hood shell by pulling upon the aft side and sliding hood towards aft aircraft. Remove four #8-32 cluster attachment screws. See Figure 13-3. Retain removed hardware for re-installation. NOTE CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 450 Disconnect two static and one pitot tube from airspeed indicator and altimeter. Remove cluster from aircraft. Remove cluster bezel by removing 10 #6-32 mounting panel attachment screws. See Figure 13-4. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 451 "Replace Annunciator Panel" on page 13-39 13.3.7 Install Instrument Cluster Use the following to install the instruments cluster. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 452 "Replace Annunciator Panel" on page 13-39 13.3.8 Access Center Stack Instruments and Switches This section contains instructions to remove and install Center Stack instrument wire connections. NFORMATION Type of Maintenance Line Level of Certification ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 453 INSTRUMENTS (AND AVIONICS) / INSTRUMENTS AND AVIONICS GENERAL MAINTENANCE 13-33 LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 10—Instrument (and Avionics) Consumables None FIGURE 13-5 CENTER STACK OVERVIEW CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 454 NAV Light Switch T9308 & T9300 TAXI Light Switch T9305 & T9303 LAND Light Switch T9304 & T9302 Bilge Pump Switch T9306 & T9309 Bilge Pump LED D9055J & D9055P Landing Gear Indicator D9045P ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 455 CENTER STACK WIRE HARNESS 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 for instruments located in the Center Console Bucket. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 456 This section contains instructions to remove and install hour meter. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 10—Instruments and Avionics Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 457 Access the hour meter. (See “Throttle Handle and Bezel Removal” on page 8-10.)(See “Throttle Handle and Bezel Installation” on page 8-13.) ERIFICATION ETHOD The procedure is complete when you have removed and installed the hour meter. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 458 Inspection Instructions 13.4.3.1 Annunciator Panel Function The following section contains information needed to test annunciator panel function. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 459 13.4.4.1 Replace Annunciator Panel The following can be used to replace the annunciator panel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required LS5000-904 (PANEL, ANNUNCIATOR) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 460 Check the operation of the annunciator panel (See “Annunciator Panel Function” on page 13-38.) ELATED NFORMATION "Install Instrument Cluster" on page 13-31 "Remove Instrument Cluster" on page 13-29 "Annunciator Panel Function" on page 13-38 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 461 Search and Rescue Satelite Aided Tracking (SARSAT), a majority of ELT false alerts occur during testing and maintenance. Call 1-800-851-3051 to cancel a false alert. 13.5.2 ELT Diagram/Schematic FIGURE 13-8 ELT ANTENNA AND TRANSPONDER ANTENNA CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 462 The following contains instructions for accessing the ELT for inspection and maintenance. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 10—Instruments (and Avionics) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 463 The ELT can now be accessed for service. The figure below shows the view looking aft into the ELT bay. Note the orientation of the toggle switch positions. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 464 The following includes directions for the inspection and function check of the ELT. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 465 Carefully remove the ELT unit from the aircraft. There is a raised flange on the ELT just aft of the forward strap. The NOTE forward strap will need to be worked around this flange to remove the ELT. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 466 Perform ELT unit self-test according to SELF TESTS of Section 9 of ACK Technologies Inc. Model E-04 ELT Installation/Operation Manual, or See “ELT Battery Self Test” on page 13-47. ERIFICATION ETHOD Inspection is verified if all ELT functional checks pass. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 467 (RCPI) once. You will hear one second of 121.5 audio on the radio, followed by either one beep from the audio alert indicator, or one beep followed by a two CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 468 "ELT Transponder and Transmitter Antenna Assembly" on page 13-55 13.5.4 Maintenance Instructions 13.5.4.1 ELT Battery Replacement Use these instructions to access the ELT battery for inspection or replacement. NFORMATION Type of Maintenance Line ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 469 Information or section 9 of the ACK Technologies Inc. Model E-04 ELT Installation/Operation Manual. ERIFICATION ETHOD After re-installation of the ELT into the aircraft, a self test must be preformed. (See “ELT Battery Self Test” on page 13-47.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 470 Locate the ELT RCPI. Use a T10 Torx driver to remove the four 6-32 screws attaching the black ICA009273 bracket to the RCPI and orange audio alert indicator, then remove the bracket and remove the RCPI. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 471 Join the halves of the RCPI case together and tighten the three remaining screws. Mount the RCPI and audio alert indicator back into the overhead console, securing them with the ICA009273 bracket and four screws. Replace the overhead console mount. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 472 10—Instruments (and Avionics) Consumables None The ELT audio alert indicator’s battery must be replaced every 10 NOTE years. NSTRUCTIONS Remove the overhead console bezel and console mount. (See “Overhead Console Component Replacement” on page 13-15.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 473 Replace the top cover, making sure the grill portion of the indicator cover is positioned over the buzzer. Mount the audio alert indicator and RCPI back into the overhead console, securing them with the ICA009273 Bracket and four screws. Replace the overhead console mount. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 474 "ELT Remote Control Panel Battery Replacement" on page 13-50 "Overhead Console Component Replacement" on page 13-15 13.5.4.4 ELT Transponder and Transmitter Replacement 13.5.4.4.1 ELT Transponder and Transmitter Antenna Replacement FIGURE 13-10 ELT TRANSPONDER AND TRANSMITTER ANTENNA REPLACEMENT ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 475 Aircraft System and Number 10—Instruments (and Avionics) Consumables Loctite 243 THREADLOCKER NSTRUCTIONS Remove top engine cowling. (See “Remove Engine Cowlings” on page 16-13.) Loosen the nuts and lock washers to remove the TRANSPONDER ANTENNA. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 476 Remove the nut and star washer to remove the ELT ANTENNA. If ground wires need to be replaced, carefully remove the adhesive bonding the eight ground wires to the cowl surface, otherwise leave ground wires in place. FIGURE 13-12 REMOVE ELT ANTENNA ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 477 Orient the four ground wires 90° from one another as shown. (See Figure 13-14.) Temporarily secure ground wires using tape. Add Loctite 243 and torque nut to 13-15 in-lbs. Ensure ground wire terminals do not rotate. FIGURE 13-13 INSTALL ELT ANTENNA CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 478 Ensure each ring terminal is at a 90° angle from one another. Orient 4x ground wires 90° from one another as shown. Temporarily secure ground wires using tape. Torque nut to 13-15 in-lbs. Ensure ground wire terminals do not rotate. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 479 INSTRUMENTS (AND AVIONICS) / ELT 13-59 SIDE VIEW FIGURE 13-15 INSTALL TRANSPONDER ANTENNA Ensure ELT and transponder antenna ground wires do not overlap and are not touching one another. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 480 13-60 INSTRUMENTS (AND AVIONICS) / ELT BOTTOM VIEW FIGURE 13-16 BOTTOM VIEW OF TOP ENGINE COWLING AFTER ANTENNAS ARE INSTALLED ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 481 E-04 ELT Installation/Operation Manual, or See “ELT Battery Self Test” on page 13-47. ELATED NFORMATION "Remove Engine Cowlings" on page 16-13 "Install Engine Cowlings" on page 16-16 "ELT Battery Self Test" on page 13-47 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 482 COMM ANTENNA—EXPLODED VIEW 13.6.3 Maintenance Instructions 13.6.3.1 Comm Antenna Removal These instructions are to be used to remove the comm antenna for transportation or repair. NFORMATION Type of Maintenance Line Level of Certification ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 483 These instructions are to be used to install the comm antenna after transportation or repair. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None Parts Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 484 The comm antenna is located on top of the horizontal tail. NSTRUCTIONS Connect the antenna to the BNC connector. Install antenna 4 8-32x1.00 screws. ERIFICATION ETHOD The task is finished when the antenna is fully installed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 485 13.7 DAC Memory Unit 13.7.1 Maintenance Instructions 13.7.1.1 DAC Memory Unit Removal The A5 contains a memory unit that records data from operations. Use this task to remove the DAC memory unit. NFORMATION Type of Maintenance Line Level of Certification...
  • Page 486 Task is complete when DAC memory unit has been removed. ELATED NFORMATION "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-install the DAC memory unit. NFORMATION Type of Maintenance Line...
  • Page 487 13.7.1.3 DAC Software Version 13.7.1.3.1 Verify DAC Software Version Use this task to verify the DAC memory unit software version. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 488 “xxxx” is a decimal file number range from 0001 to 9999. For each NOTE restart of the DAC unit or after one hour of engine operation a new data file is created, and the previous file will be closed. FIGURE 13-19 LOAD DAC DATA FILE ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 489 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 If the software is not the most current version, contact ICON to send DAC unit for software update. ERIFICATION ETHOD This task is complete upon successful verification of current version for the DAC software version.
  • Page 490 It is preferable that a calibrated test set be used, but if not readily available, the pitot-static system can be tested with simple tools such as a syringe. (See “Pitot Static Leak Check Operation” on page 13-75.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 491 Total amount of leak during the test: Upper Port:__________ft Lower Port:__________ft If the system is 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. CHANGE C2...
  • Page 492 Locate the pitot probe on the left side center wing and attach the pressure port hose to the pitot probe. Ensure that the hose is slid onto the pitot probe until it contacts the vertical part of the probe. Secure with a plastic tie wrap. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 493 Seal the right side static port with aluminum tape and ensure that an air tight seal is completed by using a plastic scraper to rub the tape around the static port. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 494 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. ERIFICATION ETHOD Double check that all connections are made correctly and that there is no strain on hoses. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 495 Ensure that the Pressure Reservoir and Vacuum Reservoir gages indicate 0 psi and 0 inHg respectively. Power on the PS-525 to 12 volts by pulling up on the power switch in the center of the box to unlock, then swinging the switch down to +12 V. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 496 Carefully open the Pressure Control valve. It will turn approximately 3/4 of a turn before the valve opens. Increase the indicated airspeed on the display to 100 knots. Carefully close the Pressure Control valve. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 497 Press the Leak Check button under the Altitude display. Press Leak Check two more times until the screen indicates 60 sec, then press the Units button to start the leak check. The ICON standard is no more than a 50 feet total leak over 60 NOTE seconds.
  • Page 498 Turn the PS-525 tester unit power to Display Off. Record the results of the pitot leak check and static leak check in the Verification Method form of the parent task. (See “Pitot-Static-AOA Leak Test Procedures” on page 13-70.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 499 Locate the upper AOA port on the left wing mid span. Using ITW Tacky tape, secure the BFST26-820 connector to the upper wing surface ensuring there is no air leak around the AOA port. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 500 Press the Leak Check button under the Altitude display. Press Leak Check two more times until the screen indicates 60 sec, then press the Units button to start the leak check. The ICON standard is no more than a 50 feet total leak over 60 NOTE seconds.
  • Page 501 Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Plastic Syringe (at least 60 mL capacity) Flexible PVC tubing that fits tightly over pitot tube ITW Tacky Tape CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 502 With the new altitude set, begin timing while tapping glass of instrument. After one minute, note the displayed altitude and record the results. ESULT Date of Test: Initials of Technician: Airspeed Reading at Time 0 sec: Airspeed Reading at Time 60 sec: Altitude Reading at Time 0 sec: ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 503 5 knots for the airspeed test as conducted above. ERIFICATION ETHOD If the system is 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. ELATED NFORMATION "Multiple Systems Controller (MSC) Replacement"...
  • Page 504 Check the altimeter needle reading against current altitude to ensure it is within the allowed tolerance shown in Table 13-3. If the reading is outside the tolerance, contact ICON for warranty, remove and replace the altimeter. (See “Replace Instrument Panel Gauge” on page 13-26.) Turn mater switch OFF.
  • Page 505 CONNECTION AT MSC Remove the four nylon tubes connecting Pitot-Static-AOA System to MSC, mark each of them for reconnection. Check the connections between MSC ports and tubing for issues; replace any damaged parts. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 506 Preston PS-525 Pitot-Static Test Set (or equivalent) Parts Required None Aircraft System and Number 10—Instruments (and Avionics) Consumables None NSTRUCTIONS Locate the left wing hinge. (See “Remove Left Wing” on page 17-9. Steps one to three.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 507 Perform a Pitot-Static-AOA System Leak Check to confirm no leaks at the MSC connections before proceeding. (See “Pitot-Static-AOA Leak Test Procedures” on page 13-70.) Reinstall the wing. (See “Install Left Wing” on page 17-12.) ERIFICATION ETHOD This task is complete when AOA system is fully functioning. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 508 13-88 INSTRUMENTS (AND AVIONICS) / PITOT-STATIC-ANGLE OF ATTACK (AOA) SYSTEM ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 509: Landing Gear

    Main Landing Gear (MLG) Wheel and Axle Installation ......14-48 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 510 Maintenance Instructions ............14-83 Aft Nose Landing Gear (NLG) Door Mechanism Removal, Installation, and Rigging14-83 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 511 The self-centering, full 360° castering nose wheel allows for ease of movement when moving the A5 on the ground and aligns the nose wheel to the correct position for gear retraction. Steering is accom- plished while taxiing via differential braking actuated by toe pressure on the rudder pedals.
  • Page 512 14-4 LANDING GEAR / DIAGRAM/SCHEMATIC 14.2 Diagram/Schematic ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 513 Jack the aircraft using the built-in jack points. (See “Empty Weight and CG Measurement While on Jackpoint Scales” on page 3-32.) Extend the landing gear to its deployed position. With the aircraft jacked and level, zero a digital protractor along the longer of the two pushrods. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 514 The following section contains the information required to evaluate the rigging of the landing gear components in the retracted position. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 515 Verify that the landing gear has fully retracted and the nose gear doors have withdrawn completely to provide a smooth closed outer surface. Extend landing gear. Turn off master switch. Replace Aft Bulkhead Baggage Panel. Lower the aircraft. ERIFICATION ETHOD Verify that each check is passed successfully. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 516 Inspect the main landing gear system. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Wing Jack Point Adapter—ICA009750 Parts Required None Aircraft System and Number 11—Landing Gear Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 517 Inspect both legs of the main landing gear for any hairline fractures. Inspect both main landing gear boots for wear or tears. Check the bonded joints between boot and leg and between boot and Seawings™. Use care to thoroughly inspect along the entire CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 518 Parts Required None Aircraft System and Number 11—Landing Gear Consumables None This task can be readily combined with the Landing Gear Retraction and Extension Time task. (See “Retraction and Extension Time” on page 14-12.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 519 Verify icon 3 (see illustration) is lit. Move Landing Gear Lever to UP position. Verify icon 2 (see illustration) is lit while the landing gear retracts. Verify icon 1 (see illustration) is lit after the landing gear finishes retracting. ERIFICATION ETHOD If each of the three lights indicated properly at DOWN, UP, and in transit when commanded, then the check is successful.
  • Page 520 Move Landing Gear Lever to UP position. Using stop watch, immediately start timer for retraction. Stop timer when center consoled UP indicator lights. Record elapsed time. Move Landing Gear Lever to DOWN position. Immediately start timer. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 521 The following should be used to inspect the nose wheel centering operation. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 11—Landing Gear Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 522 Lift the nose by hand by firmly grasping the bow ring to ensure proper centering of the nose wheel. ERIFICATION ETHOD Check is successful if hardware is in good condition and nose wheel rotates to center when lifted off of the ground. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 523 Wing Jack Point Adapter—ICA009750 Parts Required None Aircraft System and Number 11—Landing Gear Consumables None NSTRUCTIONS Check the “NOSE GEAR” or “MAIN GEAR” fuses by inspecting the Overhead Console for the desired blown fuse. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 524 "Replace Overhead Console Fuses" on page 13-18 14.3.8 Landing Gear Excessive Friction Check Use the following procedure to check for excessive friction in either the MLG or NLG installation. NFORMATION Type of Maintenance ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 525 Retracting and extending the landing gear verifies there is excessive friction within the system. Contact ICON for further instructions. ELATED NFORMATION "Empty Weight and CG Measurement While on Jackpoint Scales" on page 3-32 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 526 ERIFICATION ETHOD Review task from Beringer Wheel and Brakes Maintenance Manual and verify all steps completed. Visually inspect the system for any anomalies. Test the braking system thoroughly during taxi before attempting flight. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 527 Use the thumb wheel to set the affected switch to the desired position. Torque the jam nut to 36-40 in-lb to secure the position of the limit switch. Power up the aircraft, and actuate the landing gear to verify adjustment. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 528 Power up the aircraft, and actuate the landing gear to verify adjustment. ELATED NFORMATION "Right Instrument Panel Top Panel Removal" on page 8-17 "Right Instrument Panel Top Panel Installation" on page 8-18 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 529 Rudder Pedal Connector Lines Replacement Use the following procedure to replace the rudder pedal connector lines. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Specific Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 530 Wrap the entire length of each brake line with spiral wrap. Route the line as shown in Figure 14-6. FIGURE 14-6 BRAKE LINE REPLACEMENT Connect the brake line to the adapter fittings on the master cylinders. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 531 Parts Required HDB01 Stainless Steel Braided Brake Hose HYD-008P B-nut or HEA01 Banjo fittings as required T25F-C0 Spiral Wrap TY24MX Cable Tie Aircraft System and Number 11—Landing Gear Consumables F4TAPEBLACK Silicone Tape Smooth-On Sil-Poxy CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 532 Verify that the line is routed correctly and the pilot’s rudder pedals move through their full travel and adjustment range freely with no brake line interference. Bleed the brakes per the procedure in the Beringer Manual. Check for correct operation and no leaks. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 533 Use a 14mm wrench to remove the banjo bolt and two copper washers at the MLG brake caliper. Cut and remove all the cable ties holding the brake line to the structure. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 534 MLG leg guides. Do not put a twist in the line. Use a HYD-003P Banjo bolt and two HYD-005B copper washers as shown in Figure 14-8. Torque the Banjo bolt to 140 in-lb ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 535 Mark the location on the brake line that will secured to the mounts. Wrap a 3-inch length of silicone tape around the brake line at each mount location, then secure the line to the mounts using TY24MX cable tie at each of the two locations (see Figure 14-10). CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 536 Connect the brake line B-nut to the parking brake valve, then use a 7/16 wrench to hold the AN816-3D fitting on the forward port of the parking brake valve, and a 1/2 wrench to torque the B-nut to 30-40 in-lb (see Figure 14-12). ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 537 Use the following procedure for preparing and cutting the brake line to length and adding banjo fittings. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required HDB01 Stainless Steel Braided Hose CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 538 Clean any debris from cut end and gently reshape back to circular section with a pair of pliers (see Figure 14-13). FIGURE 14-13 GENERAL BRAKE LINE TERMINATION Disassemble hose end fitting into its component parts, socket, olive, and main body (see Figure 14-14 for example using a banjo fitting). ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 539 (see Figure 14-15). FIGURE 14-15 GENERAL BRAKE LINE TERMINATION Grasp the hose and push the olive against a flat surface until the PTFE liner contacts the shoulder inside the olive. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 540 "Aft Lines Replacement" on page 14-25 "Parking Brake Valve Replacement Procedure" on page 14-32 14.5.1.3 Parking Brake Valve Replacement Procedure Use the following procedure to replace the parking brake valve. FIGURE 14-16 PARKING BRAKE VALVE AND COMPONENTS ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 541 1/2” wrench to disconnect the B-nut of the brake lines at the parking valve. Cap or plug the openings to minimize fluid loss. ERIFICATION ETHOD Verify that the parking brake valve is fully removed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 542 Torque screw to 13 in-lb. Remove the plugs from parking valve. Apply a 360° bead of threadlocker to the leading threads of the NPT thread end of the fittings. Install fittings into valve until finger tight. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 543 Connect AFT brake lines to parking brake valve. Torque fittings to 90-132 in-lb. Check that hard- ware is secure. FIGURE 14-20 INSTALLATION OF BRAKE LINES ONTO PARKING VALVE Connect brake line fittings to parking brake valve and lower adapters on brake master cylinders. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 544 Torque 2x bolts to 13-15 in-lb. Check that hardware is secure. Bleed the brakes per the procedure in the Beringer Manual. ERIFICATION ETHOD Verify that the parking brake valve is fully assembled. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 545 “Baggage Floor Removal” on page 3-41.) Jack aircraft so that landing gear is clear of ground. Remove the aft bulkhead baggage panel. (See “Baggage Sidewall Panel Removal” on page 3-43.) Release the parking brake. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 546 "Main Landing Gear (MLG) Boot Installation" on page 14-42 "Inspect Flap Rigging" on page 9-65 14.6.1.2 Main Landing Gear (MLG) Installation The following procedure should be used to install the main landing gear (MLG). NFORMATION ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 547 Apply Tef-Gel to the AN3C27A bolt and install through the bellcrank and shaft with a NAS1149C0332R washer under its head. Torque to 20 in-lb Position the left MLG assembly under the left Seawings™. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 548 (See “Baggage Sidewall Panel Installation” on page 3-45.) Lower the aircraft off of the jacks. ERIFICATION ETHOD The main landing gear actuator should fall within the range specified in the rigging procedure. (See “Inspect Flap Rigging” on page 9-65.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 549 Break the bonds between the leg and the boot and between the boot and the Seawings™. Slide the boot over the leg and caliper to remove. ERIFICATION ETHOD Procedure is complete when the MLG boot has been completely removed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 550 Retract the landing gear halfway up from the extended position. Slide the boot up until the boot’s flange fits well against the mating flange on the Seawings™, with boot in a relaxed state. The ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 551 Install the axle and wheel assemblies using the MLG Wheel and Axle procedure. (See “Main Landing Gear (MLG) Wheel and Axle Installation” on page 14-48.) Leave the aircraft on the jacks CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 552 30 second dwell between each up or down actuation. The verification check shall be considered complete only if the system actuates without fuse failure. If fuse failure occurs, contact ICON Owner Support for further instructions. ELATED NFORMATION "Re-Bond Main Landing Gear (MLG) Boot"...
  • Page 553 "Main Landing Gear (MLG) Boot Installation" on page 14-42 14.6.1.6 Main Landing Gear (MLG) Wheel and Axle Removal Use the following procedure to remove the MLG wheel and axle. NFORMATION Type of Maintenance Line Level of Certification CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 554 NOTE NSTRUCTIONS Raise the aircraft on jacks. (See “Empty Weight and CG Measurement While on Jackpoint Scales” on page 3-32.) Remove the safety wire that secures the brake rotor to the MLG wheel. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 555 WHEEL/BRAKE ROTOR DETAIL. Remove MLG wheel seal cap. Remove cotter pin, MLG wheel nut, wheel, and spacer. FIGURE 14-23 WHEEL NUT DETAIL. Remove brake rotor from caliper and store in a clean location. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 556 NSTRUCTIONS Attach the brake caliper to the main landing gear axle using the retained countersunk screws. ® Coat the screws with a thin layer of Tef-Gel on installation, torque them to 88 in-lb. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 557 Apply MOLYKOTE™ grease to the axle threads and tighten wheel nut to 216 in-lb per the Beringer Manual. FIGURE 14-24 WHEEL AXLE DETAIL. Install a cotter pin through the axle and reinsert wheel seal cap. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 558 Jack the aircraft until the landing gear is safely off the ground. Remove the aft bulkhead baggage panel. (See “Removal and Installation of Inspection Panels and Fairings” on page 3-34.) Disconnect the MLG actuator connector at the aircraft harness. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 559 Parts Required None Aircraft System and Number 11—Landing Gear Consumables None NSTRUCTIONS Install an ICA008138 bearing into the attachment bore at the motor-end of the actuator. Install an ICA008139 bushing into the above bearing. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 560 Use the following task to adjust the main landing gear (MLG) rigging when the landing gear is up. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required ICA009750 (Wing Jack Point Adapter) Parts Required None Aircraft System and Number ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 561 (See Figure 14-25.) FIGURE 14-25 PAPER CHECK BETWEEN MLG STRUT AND STOP Remove weight. ERIFICATION ETHOD A single sheet of paper should slide with a slight drag between the MLG strut and stop. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 562 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). With landing gear down, zero a digital protractor along the longer of the two pushrods. FIGURE 14-26 MAIN LANDING GEAR INSTALLATION ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 563 To adjust the position of the actuator, loosen the jam nut on the actuator switch. To adjust the landing gear DOWN position, adjust the limit switch closest to the rod end accord- ingly. Torque jam nut to 36-40 in-lbs. ERIFICATION ETHOD The protractor’s measurement should read 3.822±.237°. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 564 Inspect the nose landing gear system. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Wing Jack Point Adapter—ICA009750 Parts Required None Aircraft System and Number 11—Landing Gear Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 565 (left hand fork) and counter clockwise (right hand fork). This will override the locking mechanism and allow the user to evaluate the door operation for smoothness, as well as play in the mechanical linkages. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 566 14.7.2.1 Nose Landing Gear (NLG) Wheel Removal Use the following procedure to remove the nose landing gear wheel. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 567 Use a 7/16 wrench to remove the two AN4C11A bolts on either side of the NLG fork. Slide the wheel assembly out of the fork. Remove the ICA011894 spacer and AV-ICON-002 axle. Proceed to section “Nose Wheel Tire Leak” to add sealant to the Nose Wheel.
  • Page 568 Start this procedure with a complete Beringer nose wheel and tire assembly (see Beringer Wheel and Brake Maintenance Manual). NSTRUCTIONS Slide the AV-ICON-002 axle into the wheel assembly. Slide the ICA011894 spacer onto the end of the axle. Position the wheel assembly into the NLG fork.
  • Page 569 Use 5/8 and 22/32 wrenches to remove the two AN7C14A bolts and MS21044C7 nuts that attach the NLG trunnion to the NLG box. For the aircraft right side, the nut is accessed by reaching through the battery box (see below). CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 570 14.7.2.4 Nose Landing Gear (NLG) Leg Assembly Installation Use the following procedure to install the nose landing gear leg assembly. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 571 From the inside of the fuselage, install the ICA007417 bushings and MS21044C7 nuts onto the AN7 bolts, the bushings being positioned inside the flanged bearings in the NLG box. Apply ® Tef-Gel to the bolt threads. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 572 Locate the NLG drag link into position in the bracket on the NLG leg and install the ICA007756 wrist pin. Install retaining ring S73HW2-100-043 into the groove in the wrist pin, securing it in place. Assemble the forward NLG door torsion springs onto the ICA008817 mounts as shown. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 573 Locate the forward NLG door into position so that the pivot holes align, deflecting the springs in the process. Slide the AN526 screw in place, along with Z4110-316SS binding post and its NAS11490332R washer. Tighten snugly. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 574 Parts Required None Aircraft System and Number 11—Landing Gear Consumables ® LOCTITE 603™ ® Tef-Gel NSTRUCTIONS Remove forward landing gear door assembly. (See “Removal and Installation of Inspection Panels and Fairings” on page 3-34.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 575 SFR4ZZ bearing (larger outer diameter side). Torque the screw to 25 in-lb Remove the safety wire installed in Step 3. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 576 This task is used to remove the nose landing gear steering bearing before it is replaced. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Nose Gear Bearing Installation/Removal Tool Parts Required None Aircraft System and Number 11—Landing Gear Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 577 Remove the nose wheel fork assembly out of the bottom of the leg. Place ICON 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 inside the center of the tool.
  • Page 578 This usually takes 3-4 rounds of wiping. Remove contaminants from the outside of the bearing by cleaning with isopropyl alcohol until cloth wipes clean. ERIFICATION ETHOD Bearing is clean and free of contaminants. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 579 Mask nose landing gear so no adhesive ends up on the paint. Apply Miller 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.
  • Page 580 Bearing should end up flush on top and bottom of the nose landing gear leg. Remove ICON nose landing gear bearing install/removal tool. Clean up adhesive that squeezed out during the installation. Excess uncured adhesive may be removed with a cloth and isopropyl alcohol.
  • Page 581 14.7.2.7.1 Nose Landing Gear Actuator Replacement Use the following task to replace the nose landing gear actuator. NFORMATION Type of Maintenance Line Level of Certification A&P Task Specific Training Required Special Tools Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 582 Use the following task to install and replace the nose landing gear actuator. For rigging only, proceed to step five. NFORMATION Type of Maintenance Line Level of Certification A&P Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 583 (AN4C10A) and washer (under bolt head) (NAS1149C0432R) as shown in the two graphics ® below. Apply Tef-Gel to bushing and bolt threads and shank prior to assembly. Torque bolt to 54 in-lb FIGURE 14-28 ACTUATOR DETAILED VIEW CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 584 NLG box is 3-4 lbs measured at the wheel axle. ERIFICATION ETHOD Jack up aircraft and swing both main and nose gear together 10 times. Perform return to service flight. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 585 Using Test box, verify that when in full retract position, the NLG leg does NOT contact the NLG stop. Use Test box to position the NLG such that it is approximately half way between fully extended and fully retracted. Attach 5lb weight (ITL012297) to NLG wheel in the location shown. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 586 14.7.2.9 Nose Landing Gear (NLG) Rigging and Rigging Check with Landing Gear Down Use this procedure to rig the NLG with gear down. See Step 3 for rigging check instructions. NFORMATION Type of Maintenance Line Level of Certification ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 587 The NLG Actuator will stop automatically when it reaches the full extend position. Allow gear to extend under its own weight (no additional weight NOTE added). Insert Rig Pin through the holes identified in the image. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 588 Use the following procedure if it is suspected that the Nose Wheel Tire has a leak. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 589 After leaks have been sealed, install Nose Wheel. (See “Nose Landing Gear (NLG) Wheel Instal- lation” on page 14-59.) ERIFICATION ETHOD Allow aircraft to sit for 24 hours. After 24 hours spray soapy water to verify no leaks. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 590 14-82 LANDING GEAR / NOSE LANDING GEAR ELATED NFORMATION "Nose Landing Gear (NLG) Wheel Removal" on page 14-58 "Nose Landing Gear (NLG) Wheel Installation" on page 14-59 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 591 Doors and mechanisms that need replacement or repair. Verify Click Bond studs have been installed. The studs are bonded into the NLG box as shown. Repeat this step for both LH and RH sides. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 592 14-84 LANDING GEAR / AFT NOSE LANDING GEAR DOOR Verify that the door bushings have been installed into the forward bellcrank pockets as shown. Repeat this step for both LH and RH sides. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 593 LANDING GEAR / AFT NOSE LANDING GEAR DOOR 14-85 Verify that the door bushings have been installed into the aft bellcrank pockets as shown. Repeat this step for both LH and RH sides. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 594 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 the specification identified. The LH side is a mirror image. Repeat for the LH side. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 595 MS21043-4 (31) NAS1149C0332R (33) NAS1149C0432R Prepare the door stops by installing one helicoil insert into the RH door stop. Repeat for the LH side. Item No Part No 3591-3N285 (21) ICA010044 (24) ICA010082 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 596 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. Repeat for the LH side. Item No Part No 75101 (15) AN3C4A ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 597 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 forward RH bellcrank. Item No Part No (10) 97395A485 (19) ICA010035 (23) ICA010059 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 598 RH and LH bellcrank pockets as shown using the hardware listed. Torque all hardware as specified. Ensure that bolt (14) goes through both the door stop and through NOTE the bellcrank. Item No Part No 6362K112 75101 (14) AN3C30A (29) MS21043-3 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 599 LH and one for the RH. Ensure the spring is connected to the smaller of the two holes on NOTE the spring clip. Item No Part No 9654K196 (25) ICA010385 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 600 Orient pushrod subassembly so that the RH threaded rod end is at NOTE the top and the LH threaded rod end is at the bottom. Item No Part No (11) AN3C10A (18) ICA008887 (28) ME000270 (29) MS21043-3 (31) NAS1149C0332R ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 601 RH forward bellcrank using the hardware shown. Torque to the specification listed. Repeat for the mirror-image LH side. Item No Part No (12) AN3C11A (18) ICA008887 (29) MS21043-3 (31) NAS1149C0332R (32) NAS1149C0363R CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 602 Confirm that the door locks in the open position. Torque the jam nuts to 53 in-lb . Repeat this step for the mirror-image LH side. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 603 Connect the spring clip to the Click Bond stud and secure with the hardware shown. Torque to the specification show. Repeat for the mirror-image LH side. Item No Part No 93013A605 (29) MS21043-3 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 604 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. Item No Part No 6362K112 (23) ICA010059 75101 (13) AN3C12A (29) MS21043-3 (19) ICA010035 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 605 Install doors to the bellcranks by loosely installing the RH and LH doors to the bellcranks using the hardware shown. Item No Part No 10F87MTT3/50TL (26) ME000256 (29) MS21043-3 (31) NAS1149C0332R (27) ME000258 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 606 Adjust the position of the door in the bellcrank slot. • Add shims between the bellcranks and the doors with a maximum of four shims installed per bellcrank. Item No Part No (201) ICA010389 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 607 LANDING GEAR / AFT NOSE LANDING GEAR DOOR 14-99 ERIFICATION ETHOD Inspect the Nose Landing Gear per the inspection procedure. (See “Nose Gear Inspection” on page 14-56.) ELATED NFORMATION "Nose Gear Inspection" on page 14-56 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 608 14-100 LANDING GEAR / AFT NOSE LANDING GEAR DOOR ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 609: Placards And Markings

    Aircraft Data Plate ............15-12 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 610 Propeller Warnings ............15-14 ICON A5 / MAINTENANCE MANUAL...
  • Page 611 (and holder), company logos and model identification graphics; interior component paint, finishes and surface coverings; the exterior paint color scheme, associated graphics and N-numbers and the Seawing non-slip step area surface finish. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 612 Located on the overhead console. 15.2.1.2 Max Amperage for USB and 12V Accessory Port Located inside of arm rest in center console. 15.2.1.3 Maneuvering Speed Located on the left side above the ignition and master switch. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 613 15.2.1.6 Parking Brake Located next to the parking brake. 15.2.1.7 Window Removal Procedure Located on the removable window. There are two per aircraft—one on the right side and one on the left side. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 614 Located on the canopy jamb. There are two per aircraft—one on the right side and one on the left side. 15.2.1.12 Open Canopy Located above the occupant seats under the canopy latch handle. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 615 Registration numbers are for illustration only. Your aircraft registra- NOTE tion number will be different. 15.2.1.15 Fuselage Station Located in cockpit above the baggage compartment on the forward face of the wing spar and beneath the headliner panel. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 616 Located under battery charging terminals on right, inside surface of fuselage near passenger rudder pedals. 15.2.1.17 Fuses Located on overhead console. 15.2.1.18 ELT Remote Switch Located on overhead console on ELT remote control. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 617 Located on the center of the canopy; top side, next to the canopy release lever. 15.2.2.2 Danger Explosive Located on the parachute egress panel adjacent to the engine on the root of the right wing. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 618 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 parachute installation adjacent to the engine on the root of the right wing. ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 619 Located on bottom, center wing near wing fold joint forward of the locking handle. There are two per aircraft—one on the right side and one on the left side. 15.2.2.7 Tire Pressure Located on main and nose landing gear legs. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 620 Registration numbers are for illustration only. Your aircraft registra- NOTE tion number will be different. 15.2.2.11 Light Sport Located on right and left sides of aircraft nose. Color shown for reference only. NOTE ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 621 15.2.2.14Horizontal Stabilizer Tip Locks Located on the underside of the horizontal tail tips, left and right sides. 15.2.2.15Keep AOA Port Clear Located next to the AOA ports on the left wing, top and bottom leading edge. CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 622 Located on either side of the propeller on the flap fence and on the trailing edges of the Seawings™ below the propeller. Left Hand Side Right Hand Side On Right Hand, Top, Trailing Edge of Seawings™ Below Propeller ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 623 PLACARDS AND MARKINGS / PLACARDS AND MARKINGS GENERAL MAINTENANCE 15-15 On Left Hand, Top, Trailing Edge of Seawings™ Below Propeller CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 624 15-16 PLACARDS AND MARKINGS / PLACARDS AND MARKINGS GENERAL MAINTENANCE ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 625: Propulsion

    Oil Cooler and Radiator Condition Inspection ....... . 16-55 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 626 A5 Specific Oil Change Procedures ........
  • Page 627 Install Spinner Dome ............16-106 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 628 Engine Description The A5 is powered by the Rotax 912 iS Sport (912iS 2) fuel injected 4-cylinder engine, rated at 100 hp (73.5 kW) at 5,800 RPM. The 912 iS Sport (912 iS 2) is based on the proven 912 ULS engine with signif- icant upgrades to improve performance and reliability.
  • Page 629 THERMOSTAT-RADIATOR INLET COOLANT HOSE FUEL RAIL COVER CYL.1 CYL.3 EXHAUST (TO EXHAUST ASSY) OIL TANK-ENGINE ENGINE MOUNT OIL HOSE FUEL SUPPLY LINE FIGURE 16-1 VIEW LOOKING DOWN, AFT, RHS (OIL TANK NOT SHOWN) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 630 PRESSURE SENSOR FUEL RAIL COVER IGNITION COIL EXHAUST (TO EXHAUST ASSY) CYL.4 COOLANT OVER-FLOW BOTTLE CYL.2 SPARK PLUG OIL FILTER COOLANT EXPANSION TANK FIGURE 16-2 VIEW LOOKING DOWN, FWD, LHS (OIL TANK NOT SHOWN) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 631 Instructions to perform a test run on the Rotax 912 iS Sport (912 i S 2) engine. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 632 Replenish engine oil and coolant as required once engine has cooled down. If the oil filter has been replaced, re-tighten by hand after the test NOTE run on a cold engine. Screw on the oil filter until oil filter gasket is ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 633 Special Tools Required See Rotax 912 iS Sport (912 iS 2) Line Maintenance Manual Parts Required See Rotax 912 iS Sport (912 iS 2) Line Maintenance Manual Aircraft System and Number 13—Propulsion Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 634 Engine ignition Inspect engine ignition system, system such as spark plugs, ignition wires/boots, fuel injectors, and replace parts as necessary. See “Rotax 912 iS Sport (912 iS 2) Line Maintenance Manual. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 635 Engine On) (MAPS) “Rotax 912 iS Sport (912 iS 2) Heavy Maintenance Manual. Engine Ambient Clogged air filter Replace air filter. See “Replace Temperature Engine Air Filter” on page 16-48. (Advanced BIT Engine On) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 636 “Test while Gen B Commanded” “ETPU” Flashing DAC software. Check and upstate DAC ALTERNATOR software version as necessary. Alternating “Test light See “Verify DAC Software while Gen B Version” on page 13-67. Commanded”/”CAN Status Test” ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 637 The ELT antenna and the transponder antenna are attached to the CAUTION top engine cowling. NSTRUCTIONS Release 16 1/4-turn fasteners from top engine cowl using a #15 Torx driver. (See Figure 16-4.) The fasteners stay attached to the top engine cowl. NOTE CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 638 Remove cowl completely. Remove the LHS and RHS muffler fairing with the tail pipe bezel by removing nine Torx button head screws using a #20 Torx driver. (See Figure 16-5.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 639 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 LHS. FIGURE 16-6 REMOVING FAN SHROUD ASSEMBLY CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 640 Use the following instructions to install top engine cowl, fan shrouds, and exhaust fairings. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 641 Install RH fan shroud. (See Figure 16-8.) Apply LUBRICANT and install two countersunk screws with a #15 Torx driver. Apply LUBRICANT and install four #10-32 button head screws with #20 driver. Torque to 26 in-lb. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 642 Position the top engine cowl over the engine and connect the ELT and transponder coax connec- tors. Use a #15 Torx driver to secure the top engine cowl with 16 1/4-turn fasteners. ERIFICATION ETHOD The task is complete when all engine cowlings and exhaust fairings have been installed. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 643 Remove entire cowling. (See “Remove Engine Cowlings” on page 16-13.) If desired, take photos to ensure proper routing of systems on NOTE engine re-installation. Disconnect signal and ground wires at starter solenoid. Disconnect AAPTS sensor connector (near induction air filter). CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 644 Pull the engine electrical harnesses through the firewall pass-throughs until they are clear of the firewall. Lift the engine up and clear of the airframe ensuring that nothing remains connected or snags. Remove the four sets of 94150-40 rubber engine mount isolators and label them. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 645 "Install Engine" on page 16-21 "Engine 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 16-27 "Install Engine Cowlings" on page 16-16 "Remove Oil Tank"...
  • Page 646 Method A or 290-330 in-lb if using Method B. (See Figure 16-10.) FIGURE 16-9 OIL RETURN LINE FITTING LOCATION FIGURE 16-10 METHOD A VS. METHOD B (TOP) 7/8” 12-POINT CROWS FOOT WRENCH (BOTTOM) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 647 3/8” spacer. (See Figure 16-12.) If the clearance is less, lightly loosen the fitting and use a 7/8” 12-point crows foot wrench to torque the fitting. (See Figure 16-13.) Remove the spacer. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 648 Connect the grounding wire on the alternator. Torque fastener to 88 in-lb. Apply INSULATING TAPE around the wiring at each firewall opening. This tape must lie between the wiring bundle and the firewall flange to seal and prevent chafing. Apply an outer wrap of ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 649 Connect the AAPTS sensor connector (near induction air filter). Connect the signal and ground wires at started solenoid. Torque M6 nuts to 36 in-lb. Install the exhaust system and exhaust shields. (See “Install Exhaust System” on page 16-51.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 650 Special Tools Required See Rotax 912 iS Sport (912 iS 2) Line Maintenance Manual Parts Required See Rotax 912 iS Sport (912 iS 2) Line Maintenance Manual Aircraft System and Number 13—Propulsion Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 651 Use the following procedure to remove the engine mount. NFORMATION Type of Maintenance Heavy Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 13—Propulsion Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 652 Loosen the hose clamp and remove thermostat-radiator coolant hose where it attaches to the lower-right fitting at the thermostat (Figure 16-16). FIGURE 16-16 LOWER-RIGHT FITTING AT THE THERMOSTAT Remove the six M10 screws that attach the ICA007128 engine mount to the engine case (see Figure 16-17). ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 653 "Engine Removal" on page 16-19 16.1.4.7 Engine Mount Installation Use the following procedure to install the engine mount. NFORMATION Type of Maintenance Heavy Level of Certification LSA-RM Task Specific Training Required Special Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 654 Use the following to inspect the engine mount. This inspection requires the removal of the exhaust headers and mufflers along with the entire cowling. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 655 Visually inspect the engine mount and all its inclusive hardware for any failure, malfunction, excessive wear, or other anomalies. Figure 16-18 shows the engine mount with all its inclusive hardware. FIGURE 16-18 ENGINE MOUNT EXPLODED VIEW CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 656 16.1.4.9 Inspect Throttle Control for Proper Travel and Security Use the following to inspect throttle control for proper travel and security. Perform the inspection with a second person. NFORMATION Type of Maintenance Line Level of Certification ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 657 NSTRUCTIONS Remove engine cowling. (See “Remove Engine Cowlings” on page 16-13.) It is necessary to access the engine throttle lever inside the cockpit and the cable lever on the engine. (See Figure 16-20.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 658 16-34 PROPULSION / ENGINE FIGURE 16-20 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 659 PROPULSION / ENGINE 16-35 THROTTLE ASSEMBLY CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 660 Remove throttle bezel. (See “Throttle Handle and Bezel Removal” on page 8-10.) Have a helper in the cockpit move the throttle forward and backward to confirm if the cable is clear and free to move. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 661 (See Figure 16-22.) FIGURE 16-22 IDLE POSITION ADJUSTMENT FIGURE 16-23 FULL THROTTLE POSITION ADJUSTMENT CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 662 Replace engine cowl. (See “Remove Engine Cowlings” on page 16-13.) ERIFICATION ETHOD Verify that all checks listed above are within acceptable limits. If full travel not able to be obtained, contact ICON owner support. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 663 ICA012983 or 4CMPD150G TUBE (GREASE, DIELCTRIC, DC4) TT-I-735A or equivalent (ISOPROPLY ALCOHOL) The engine contains a total of four ignition coil packs located near the intake manifold at the top of the engine as shown in Figure 16-25. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 664 Turn master switch OFF. Remove ignition key. Remove engine cowl. (See “Remove Engine Cowlings” on page 16-13.) Remove two M5 Allen mounting screws on each engine ignition coil pack as shown in Figure 16-26. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 665 FIGURE 16-27 ENGINE IGNITION COIL PACK. Use a flat head screwdriver to push the connectors out of the coil pack terminals (Figure 16-28). Take extreme caution not to damage the connectors. CAUTION CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 666 Replace spiral wrap as required. Reverse engine cowl instructions to install cowl. (See “Remove Engine Cowlings” on page 16-13.) ERIFICATION ETHOD Complete the engine test run. (See “Engine Test Run” on page 16-7.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 667 Perform a visual inspection to check all gaskets, clamps, and seams for damage and/or deterio- ration. Check for cracks in the air box, particularly at the seams and corners. Such defects could cause leakage around the filter. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 668 "Replace Engine Air Filter" on page 16-48 16.1.5.1.2 Air Filter Security Inspection The following should be used to evaluate the air filter for security of connection. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 669 Apply a rotational force to the exterior surface of the air filter. The filter should stay securely fastened during this operation. ERIFICATION ETHOD If rotation or gapping occurs, the filter attachment clamps should be tightened. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 670 Cleaning Kit. The filter can be cleaned as many as 100 times and still perform up to specification. The air filter is located in the intake duct on the front of the engine cowling just above the canopy. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 671 Clean and oil using K&N Recharger Kit per K&N Air Filter Cleaning Instructions. Return air filter and clamp to intake duct flange. Tighten worm drive clamp onto intake duct flange. ERIFICATION ETHOD Run engine after re-installation of air filter and verify normal performance. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 672 Aircraft System and Number 13—Propulsion Consumables None NSTRUCTIONS Follow instructions for cleaning the air filter except replace with a new part. ERIFICATION ETHOD Run engine after re-installation of air filter and verify normal performance. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 673 16.1.6.2 Maintenance Instructions 16.1.6.2.1 Remove Exhaust System Use the following procedure to remove one side of the exhaust system. Repeat the procedure to remove both sides of the exhaust system. NFORMATION Type of Maintenance Line CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 674 Remove 2x clamps holding FWD header heat shield in place. Remove bracket from the engine and FWD header using a 7/16” socket, 5/16” socket and 5 mm hex key. Install the M6 screw, washer, and wire harness clamp. (See Figure 16-32.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 675 "Remove Engine Cowlings" on page 16-13 16.1.6.2.2 Install Exhaust System Use the following procedure to install one side of the exhaust system. Repeat the procedure to install both sides of the exhaust system. NFORMATION Type of Maintenance CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 676 Install header heat shield onto FWD header using 2x CLAMP. Align cutout in heat shield with EGT sensor boss on FWD header. Orient CLAMP such that the spring insert rests on both heat shield supports. Torque 2x CLAMP incrementally up to 27-31 in-lb to prevent deflection of heat shield. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 677 Clean pipe and apply a thin coat of LUBRICANT, ANTI-SEIZE to the last 2 inches of FWD and AFT headers. Install the muffler sub-assembly by sliding it forward onto the FWD header and onto the engine exhaust port studs. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 678 Perform the maintenance inspections on the cooling system. NFORMATION Type of Maintenance Line Level of Certification Owner/Pilot Task Specific Training Required Special Tools Required Densimeter or Glycol Tester Parts Required None Aircraft System and Number ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 679 The following should be used for inspecting the oil cooler and radiator for leaks and condition. The engine cowling needs to be removed for this inspection. See Related Information. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 680 FIGURE 16-34 OIL SYSTEM INSTALLATION WITH HOSES AND HARDWARE SHOWN. NSTRUCTIONS Remove engine cowling. (See “Remove Engine Cowlings” on page 16-13.) Visually inspect oil cooler and radiator for leaks and condition of hoses. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 681 This procedure covers draining coolant from the engine and radiator, overflow bottle, and ECS system. Perform all three or only the ones that are required for the specific maintenance situation. NFORMATION Type of Maintenance Line CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 682 Cover the radiator cap with a rag and open slowly even when sure it is cool. Open the radiator cap (1) on the expansion tank (2), shown in Figure 16-35. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 683 Drain the coolant into the engine bay; the firewall will catch the coolant and direct it out the fuselage drain hole. After draining is complete, reinstall the radiator hose on the thermostat housing and tighten its hose clamp. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 684 Remove the bleed plug on the top-right-aft corner of the radiator with a 3/16 hex wrench (see Figure 16-36). Fill coolant at the expansion tank until coolant with no bubbles flows from the radiator bleed port. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 685 "Install Engine Cowlings" on page 16-16 16.1.7.2.2 Coolant Overflow Bottle Removal Use the following procedure to remove the coolant overflow bottle. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 686 "Install Engine Cowlings" on page 16-16 16.1.7.2.3 Coolant Overflow Bottle Installation Use the following procedure to install the coolant overflow bottle. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 687 603 to the threads of a 5058K34 hose fitting. Insert the hose fitting with its seal into the vent hole as shown in Figure 16-38. Secure the hose fitting using an AN316C49 nut torqued to 44 in-lb Reinstall cap on bottle. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 688 3804 hose clamp. FIGURE 16-39 COOLANT OVERFLOW BOTTLE Install the coolant overflow bottle bracket on the engine as shown in Figure 16-40. using the ® noted hardware. Apply LOCTITE 243™ to the screw threads. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 689 Direct the free end of the Tygon hose to the bottom of the firewall near the low point drain. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 690 Fill the overflow bottle to the mid-range level with new coolant. (See “Approved Engine Coolant Grades and Capacity” on page 2-29.) Install the engine top cowling. (See “Remove Engine Cowlings” on page 16-13.) ERIFICATION ETHOD Procedure is complete when steps are finished. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 691 ICA011701 plenum box to the airframe. Remove the plenum box and place on a clean work surface. Use caution so as to avoid bending the cooling fins on radiator and oil cooler. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 692 Place the plenum box assembly into position on the airframe. ® Coat four AN3C5A bolts with Tef-Gel and, with a NAS1149C0332R washer under each bolt head, install the bolts in the four attach locations. Torque to 26 in-lb ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 693 16.1.8.1 Oil System Description The oil system in the A5 is a dry sump forced lubrication system that ensures proper lubrication of dynamic engine components. Starting at the Rotax oil tank, oil travels to the oil thermostat and then to the oil cooler.
  • Page 694 PLENUM AIR BOX OIL COOLER OIL COOLER-THERMOSTAT LINE OIL THERMOSTAT THERMOSTAT-OIL COOLERLINE PURGE HOSE TANK-THERMOSTAT HOSE OIL TANK CURTIS OIL VALVE ENGINE-TANK HOSE (RETURN LINE) THERMOSTAT-ENGINE HOSE FIGURE 16-43 OIL SYSTEM COMPONENTS—TOP, FWD, LHS VIEW ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 695 PLENUM AIR BOX OIL THERMOSTAT TANK-THERMOSTAT HOSE OIL FILTER OIL PUMP CURTIS ENGINE-TANK HOSE OIL VALVE (RETURN LINE) (DRAIN VALVE) PURGE HOSE THERMOSTAT-ENGINE HOSE (VENTILATION) FIGURE 16-44 OIL SYSTEM COMPONENTS—BOTTOM, FWD, LHS VIEW CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 696 TANK-THERMOSTAT HOSE HOSE FIGURE 16-45 OIL THERMOSTAT CONNECTIONS 16.1.8.3 Maintenance Instructions 16.1.8.3.1 Remove Oil Tank Use the following instructions to remove the oil tank. NFORMATION Type of Maintenance Line Level of Certification LSA-RM ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 697 Burp engine. (See “Engine Oil Check and Replenish” on page 16-77.) Drain engine oil. (See “A5 Specific Oil Change Procedures” on page 16-78.) Use 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.
  • Page 698 PROPULSION / ENGINE CABLE TIE CLAMP, WORM DRIVE PURGE TUBE OIL TANK MOUNT ENGINE MOUNT CLAMP, WORM DRIVE CABLE TIE ENGINE-TANK HOSE FIGURE 16-46 OIL TANK INSTALLATION. SOME COMPONENTS NOT SHOWN FOR CLARITY. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 699 FITTING, HOSE END OIL TANK IN FITTING TANK-THERMOSTAT HOSE FIGURE 16-47 OIL TANK INSTALLATION. SOME COMPONENTS NOT SHOWN FOR CLARITY. ERIFICATION ETHOD The task is complete when the oil tank has been removed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 700 Damage to oil tank may occur if it’s not used. Secure reservoir-thermostat hose to the cable tie mount using a CABLE-TIE. Secure purge hose to the engine mount using a CABLE-TIE. (See Figure 16-14.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 701 Aircraft System and Number 13—Propulsion Consumables None See A5-specific directions regarding checking and changing the oil. (See “A5 Specific Oil Change Procedures” on page 16-78.) NSTRUCTIONS Open oil tank access door on the engine cowling and remove the oil tank cap.
  • Page 702 "Coolant Radiator Removal" on page 16-67 "Coolant Radiator Installation" on page 16-68 16.1.8.3.4 A5 Specific Oil Change Procedures There are unique oil change procedures for the A5. These steps are used to drain the oil. NFORMATION Type of Maintenance Line...
  • Page 703 "Engine Removal" on page 16-19 16.1.8.3.5 Oil Cooler and Thermostat Removal Use the following procedure to remove the oil cooler. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 704 NFORMATION "Remove Engine Cowlings" on page 16-13 16.1.8.3.6 Oil Cooler and Thermostat Installation The following procedure is used to install the oil cooler and thermostat. NFORMATION Type of Maintenance Line Level of Certification ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 705 Install one o-ring on each of the two AN815-8D union fittings and thread a fitting into the oil cooler inlet and outlet so that the o-rings seal against the cooler. Torque each to 200±50 in-lb CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 706 The upper hose connects to the top of the oil tank and should be installed second. Torque the B-nuts to 200±50 in-lb Purge the oil system per the procedure in the Rotax 912iS Installation Manual. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 707 "Remove Engine Cowlings" on page 16-13 16.1.9 Fuse Box 16.1.9.1 Fuse Box Description The fuse box contains a fuse panel for the engine and two rectifier regulators on either side. 16.1.9.2 Fuse Box Diagram/Schematic FIGURE 16-48 FUSE BOX CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 708 Remove the AFT bulkhead baggage panel. (See “Removal and Installation of Inspection Panels and Fairings” on page 3-34.) Locate the fuse box in front of the AFT bulkhead, LH as shown in Figure 16-49. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 709 (browning) are apparent. (See “Remove Fuse Box and Regulators” on page 16-86.) FIGURE 16-50 FUSE BOX, REGULATOR A AND REGULATOR B ERIFICATION ETHOD The task is completed when both regulator wires installed do not show signs of discoloration. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 710 None NSTRUCTIONS Remove the AFT bulkhead baggage panel. (See “Removal and Installation of Inspection Panels and Fairings” on page 3-34.) Locate the fuse box forward of the AFT bulkhead, LH. See Figure 16-51. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 711 Connector D9106P from engine LANE B extension wire harness • Connector D9104P from engine LANE A extension wire harness FIGURE 16-52 FUSE BOX AND CONNECTORS FIGURE 16-53 REGULATOR B SIDE GROUND TERMINALS (LEFT). REGULATOR A SIDE GROUND TERMINALS (RIGHT). CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 712 (7) on one ground stud. See Figure 16-55. • For Regulator B, remove two black ground wires (7). See Figure 16-56. FIGURE 16-54 FUSE BOX EXPLODED VIEW FIGURE 16-55 REGULATOR A SIDE OF FUSE BOX ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 713 "Inspect Regulator Wires" on page 16-84 16.1.9.4.2 Install Fuse Box and Regulators Use the following task to install the fuse box and both regulators. NFORMATION Type of Maintenance Line Level of Certification LSA-RM CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 714 Repeat Step 1-6 if replacing more than one regulator. Secure the fuse box to the fuselage with four 8-32 x 0.375 screws and washers previously removed. Apply THREADLOCKER to screw threads. Torque to 7-9 in-lb. See Figure 16-57. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 715 ERIFICATION ETHOD Complete the engine test run. (See “Engine Test Run” on page 16-7.) ELATED NFORMATION "Engine Test Run" on page 16-7 "Removal and Installation of Inspection Panels and Fairings" on page 3-34 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 716 16.2.1 Description The A5 uses a Sensenich, 3-blade propeller. The blade construction 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.
  • Page 717 PROP FLANGE ROTAX 912iS FIGURE 16-58 PROPELLER INSTALLATION—VIEW LOOKING AFT, LHS 16.2.3 Troubleshooting 16.2.3.1 Propeller Assembly Instructions for assembling the Sensenich propeller prior to installation onto the Rotax engine. NFORMATION Type of Maintenance Line CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 718 NSTRUCTIONS Assemble propeller per ‘PROPELLER ASSEMBLY’ task in the latest revision of Sensenich Propellers document 3B0R5. Please contact ICON Aircraft for proper propeller pitch setting before completion of this step. ERIFICATION ETHOD Verify proper torquing of clamping fasteners and proper pitch setting.
  • Page 719 Task Specific Training Required Special Tools Required Propeller Balance System (such as ProBalancer Sport or DynaVibe GX3) Parts Required 10F75MTT3-50TL (SCREW, MACH TH, 6LOBE, CRES, 10-32X.750X.500) 10F87M773/50TL (SCREW, MACH TH, 6LOBE, CRES, 10-32X.875) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 720 Remove the top engine cowl only. (See “Remove Engine Cowlings” on page 16-13.) Install accelerometer (vibration sensor) onto the gearbox per Propeller Balance System manual. Ensure sensor is secured tightly and oriented vertically. See Figure 16-59 as an installation example. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 721 PROBALANCER SPORT ACCELEROMETER SHOWN) Route accelerometer wire through the oil access door in the engine cowl, reinstall the top engine cowl, and connect antennas. (See Figure 16-60 and “Install Engine Cowlings” on page 16-16.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 722 Secure the optical tachometer from the Propeller Balance System to the top of the engine cowl with tape about 9 to 12 inches from the propeller. (See Figure 16-61.) FIGURE 16-61 PHOTO TACHOMETER LOCATION ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 723 Perform propeller balance using selected Propeller Balance System and its manual. After the system runs the test, it will output a vibration magnitude in inches per second (IPS) and suggest locations for adding weight. Engine speed should be 5000-5100 RPM during balancing. NOTE CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 724 26 in-lbs with a T20 Torx driver. (See Figure 16-64.) The original screws may be replaced with longer screws, but the NOTE additional weight must be accounted for. Ensure there are at least two threads protruding out of the nut plate. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 725 Reinstall the engine cowl and connect antennas. (See “Install Engine Cowlings” on page 16-16.) ERIFICATION ETHOD Ensure the spinner dome screws are torqued to spec and the vibration magnitude is less than 0.08 IPS. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 726 Aircraft System and Number 13—Propulsion Consumables None NSTRUCTIONS Remove propeller per ‘PROPELLER REMOVAL’ task in the latest revision of Sensenich Propel- lers document 3B0R5. ERIFICATION ETHOD Visually verify propeller is not mounted to engine. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 727 Complete propeller assembly. (See “Propeller Assembly” on page 16-93.) Install propeller per ‘PROPELLER INSTALLATON ON ENGINE’ task in the latest revision of Sensenich Propellers document 3B0R5. ERIFICATION ETHOD Verify fastener torque and verify propeller tracking is within 3/16 inch. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 728 Hub repairs are to be made in accordance with ‘MINOR HUB REPAIRS’ procedure. Reinstall propeller assembly onto the engine. (See “Propeller Installation Onto Engine” on page 16-103.) ERIFICATION ETHOD Visually examine that damage and repair and within the limits specified in the Sensenich document. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 729 Mark the spinner dome orientation to the bulkhead so it can be reinstalled at the same orienta- tion. Remove the six Torx fasteners with a T20 Torx driver. Document the specific fastener and washer for each mounting hole during removal. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 730 Install the six Torx fasteners with Tef-Gel and washer stacks in their original unique configura- tion. Tighten Torx fasteners into locking nut plates and torque to 26 in/lbs with a T20 Torx driver. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 731 Remove all orientation marks. ERIFICATION ETHOD The task is complete when the spinner dome has been reinstalled. ELATED NFORMATION "Condition and 100-Hour Inspection—Engine and Propeller" on page 3-21 "Balance Propeller" on page 16-95 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 732 16-108 PROPULSION / PROPELLER ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 733: Wing

    Wing Lock Catch Adjustment ..........17-36 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 734 Includes: spars, skins, ribs, flap and aileron structures and counterbalances, control surface hinges; integral or mounted aircraft/wing hand-holds, tie downs and mooring cleats, mid, forward, and aft wing pins, and the landing gear position verification mirror. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 735 Rotate the wing back in the opposite direction from step two (to avoid twisting in the light wiring and/or AOA or fuel drain tubing). Re-lock the wing into flying position. ERIFICATION ETHOD Water removed from the tip is now free to drain from holes at the wing root. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 736 Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required See Manual Tap Test Parts Required None Aircraft System and Number 14—Wing Consumables None FIGURE 17-1 INTERNAL STRUCTURAL LAYOUT OF WING ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 737 The following can be used for the general inspection of the exterior and interior wing control systems. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 14—Wing Consumables CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 738 The following is to be used for inspecting the wing bonded joints, cracks, or delaminations. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required Borescope Parts Required None Aircraft System and Number 14—Wing Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 739 Using a borescope, flashlight, and viewing mirror as appropriate, visually inspect all accessible bond lines for cracks or damage. ERIFICATION ETHOD Any cracks found should be investigation further. Do not fly the airplane and contact ICON for further instructions. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 740 17-8 WING / WING GENERAL MAINTENANCE 17.3 Wing General Maintenance 17.3.1 General Wing Inspection The following should be used to inspect the left and right wings of the A5. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required...
  • Page 741 Level of Certification LSA-RM Task Specific Training Required Special Tools Required A second person and a ladder are needed to hold the wing. Parts Required None Aircraft System and Number 14—Wing Consumables None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 742 Pull the wing outward about a foot and rest securely on a ladder. Note the interlocking pins, the flap system interconnect piston, and the ailerons interlocking clam shell system. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 743 Disconnect the electrical connector from the protruding pigtail. Disconnect the AOA high pressure tube and low pressure tube on one side of the push-on tube connectors. Disconnect the fuel vent tube on one side of the push-on tube connector. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 744 Task Specific Training Required Special Tools Required A second person and a ladder are needed to hold the wing. Parts Required 2X—wing U-joint retaining ring—P/N 98410A110 Aircraft System and Number 14—Wing Consumables None ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 745 Carefully inspect wing fold joint to ensure proper latching and security. 17.3.4 Remove Right Wing Instructions for taking the right wing off of the airplane. NFORMATION Type of Maintenance Line Level of Certification LSA-RM CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 746 When wing is successfully removed from the airplane, this task is complete. 17.3.5 Install Right Wing Instructions for installing the right wing onto the airplane. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 747 ERIFICATION ETHOD Carefully inspect wing fold joint to ensure proper latching and security. 17.3.6 Wing Hang Pin Replacement Use the following procedure to replace the wing hang pin. NFORMATION Type of Maintenance Line CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 748 The procedure is finished when all the steps have been completed. 17.3.7 Wing Trailing Edge Light Fence Replacement Use the following procedure to replace the trailing edge light fence. NFORMATION Type of Maintenance ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 749 Trim 70006436714 black VHB tape to the appropriate flat pattern. The LH patterns are shown, use mirror image for RH patterns. Apply VHB tape in the channel of the fence so that tape lies entirely inside of channel. Install the fence. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 750 17-18 WING / WING GENERAL MAINTENANCE ERIFICATION ETHOD The procedure is complete when the trailing edge light fence is installed. ELATED NFORMATION "Use of VHB Tape for Installations and Repairs" on page 4-12 ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 751 Support the flap with a cradle from below or with a helper. Remove the AN4C13A bolt, MS21043-4 nut, and two NAS1149C0432R washers that attach the flap pushrod to the flap surface of the affected flap. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 752 Align the hinges flap to wing and install the washers and pins at each of the three hinge locations per flap as shown in Figure 17-2. To minimize the gap between hinge elements, use 95630A460PTFE washers as needed but with a minimum of one on each side of the flap hinge ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 753 Install the AN4C13A bolt, MS21043-4 nut and two NAS1149C0432R washers that attach the flap pushrod to the flap surface of the affected flap (see Figure 17-3). FIGURE 17-3 FLAP SURFACE ERIFICATION ETHOD Verify correct flap operation and rigging. (See “Inspect Flap Rigging” on page 9-65.) CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 754 Remove affected flap pins by removing snap rings (XSC-113) or cotter pins as needed. Remove and inspect pins by measuring the minimum pin diameter with a mircrometer or caliper. If they are less than .0175”, are loose or appear worn, replace. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 755 Inspect the flap system for proper function. (See “Inspect Flap Rigging” on page 9-65.) ELATED NFORMATION "Inspect Flap Rigging" on page 9-65 "Flap Surface Removal" on page 17-19 "Flap Surface Installation" on page 17-20 CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 756 Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 14—Wing Consumables None NSTRUCTIONS Remove the wing lock handle using the procedure. (See “Wing Lock Handle Removal” on page 17-28.) ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 757 Pull the plate assembly out of the BL38 Rib and disconnect it from the aircraft electrical harness ERIFICATION ETHOD The procedure is complete when the wing lock switch mounting plate has been removed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 758 98408A116 (RETAINING RING, SIDE-MOUNT EXT, CRES, .125X.020) 98408A120 (RETAINING RING, SIDE-MOUNT EXT, CRES, .250X.029) MS21043-04 (NUT, SLFLKG, RDC HEX, CRES, 4-40) MS21043-06 (NUT, SLFLKG, RDC HEX, CRES, 6-32) Aircraft System and Number 14—Wing ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 759 See Figure 17-5. The other micro switch senses the position of the lock handle. Gently deflect it, verify free motion and an audible click. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 760 Fold wing. (See “Wing Fold Procedure” on page 18-3.) Unlatch the wing from the horizontal tail and pull it fully aft. Support it in this position by hanging the wing tip with straps from an engine hoist or other suitable arrangement. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 761 Press the wing lock bushing out of the handle if necessary, making note of its orientation. Use a slot-head screwdriver to remove thee spring detent from the handle. FIGURE 17-6 WING LOCK HANDLE ERIFICATION ETHOD The procedure is complete when the wing lock handle has been removed. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 762 MOLYKOTE™ NSTRUCTIONS Clean and inspect all parts and replace those that are not serviceable or if their condition is ques- tionable. It is recommended that all retaining rings be replaced with new ones. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 763 Also, note that the longer the two links and the longer the two locking pins connect and face aircraft forward, and the shorter the two, face aircraft rearward. FIGURE 17-7 WING LOCK HANDLE INSTALLATION CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 764 17-32 WING / WING LOCK FIGURE 17-8 WING LOCK HANDLE FIGURE 17-9 WING LOCK HANDLE FIGURE 17-10 WING LOCK HANDLE ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 765 Use the following procedure to replace components on the assembly after it is out of the wing. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 766 6C37MTT3 screws and MS21043-06 nuts. Install lever switch ICA009633 (L/H), ICA009632 (R/H) and pawl switch ICA009635 (L/H), ICA009634 (R/H) into the lock mechanism using two 92949A118 screws, 98019A309 washers, and 90715A005 nuts. ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 767 Install the extended latch pawl into the lock mechanism with two ICA008395 pins, four new 98408A116 retaining rings, and two 95630A234 washers. The pins should slide in easily by hand. Ensure that new retaining clips are used. CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 768 NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 14—Wing Consumables ® LOCTITE 243™ ICON A5 / MAINTENANCE MANUAL CHANGE C2...
  • Page 769 Insert the ball, then the spring into the housing. Install the set screw so that the spring is compressed against the ball and the head of the screw is set to a depth of .06±.01 below flush (see Figure 17-12). CHANGE C2 ICON A5 / MAINTENANCE MANUAL...
  • Page 770 7±2 lb . Adjust the housing set screws equally, together in or out, to achieve this force. ELATED NFORMATION "Wing Lock Handle Installation" on page 17-30 ICON A5 / MAINTENANCE MANUAL CHANGE C2...

  • Page 771: Wing Fold Mechanism

    Wing Fold Mechanism Security ..........18-12 CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 772 Includes mechanisms, linkages, actuators, locks and indicating/warning subsystems. Also includes the horizontal tail removable or hinged tip. Excludes mid, forward, and aft wing pins & receptacles, which are included in the Wing & Fuselage systems. ICON A5 / MAINTENANCE MANUAL CHANGE C0...
  • Page 773 The manual wing fold system allows the wings to be rotated and folded back along the fuselage, reducing the A5 width from approximately 35 feet to 8 feet for trailering, storage, and maintenance. The wing fold mechanism was designed to be simple, allowing one person to complete the task in a few minutes with no tools required using the following simple procedures.
  • Page 774 "Wing Fold/Extend Additional Information" on page 18-6 "Wing Fold Roll Bellcrank Roller Replacement" on page 18-11 18.2.1.2 Wing Extend Procedure Use the following procedure to extend the wing. NFORMATION Type of Maintenance Line ICON A5 / MAINTENANCE MANUAL CHANGE C0...
  • Page 775 Line up wing with fuselage, ensuring both fore/aft and up/down position is correct. Push wing in to the stop, noting that slight fore/aft and vertical motion may be required to fully seat wing. Immediately rotate the red wing lock handle into the locked position. CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 776 "Wing Fold Rinse" on page 4-7 "Wing Fold/Extend Additional Information" on page 18-6 18.2.1.3 Wing Fold/Extend Additional Information Helpful reference information about the wing folding system on the A5. This is not a maintenance, repair, or alteration task. • With both wings folded, the aircraft is light on the nose (tail heavy). Therefore, the wings should not be folded on an incline or the aircraft may tip onto its tail.
  • Page 777 Special Tools Required Caliper and/or Micrometer Parts Required ICA007614 (WING LOCKING PIN, FWD), if replacement needed ICA007615 (WING LOCKING PIN, AFT), if replacement needed Aircraft System and Number 15—Wing Fold Mechanism Consumables MOLYKOTE™ G-4700 CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 778 18-8 WING FOLD MECHANISM / TROUBLESHOOTING FIGURE 18-1 WING PINS LOCATION. FIGURE 18-2 WING PIN DIMENSIONAL CHECKS. ICON A5 / MAINTENANCE MANUAL CHANGE C0...
  • Page 779 Visually inspect all wing pins and bushings for wear or damage. Measure the locking pin diameters on both the left and right wings and compare to the target values in the table below. CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 780 If the wing pin dimensions are above the target values and the bushing dimensions are below the target values, then the wing pin fit is acceptable. 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 instructions.
  • Page 781 Perform the procedure below to replace this bearing. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 15—Wing Fold Mechanism Consumables MOLYKOTE™ CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 782 "Wing Fold Procedure" on page 18-3 18.3.2 Wing Fold Mechanism Security The following should be used to inspect the wing fold mechanism security and should be completed after the wings have been folded. NFORMATION Type of Maintenance ICON A5 / MAINTENANCE MANUAL CHANGE C0...
  • Page 783 With the wing fold mechanism exposed, actuate the wing fold handle to validate that there is full positive detent at the end of the handle rotation while also exhibiting smooth motion throughout the range. With the handle unlatched, check for excessive freeplay of the handle. CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 784 Validate that the wire harness is in good working condition and is free of any wear and tear. Replace the wing access panel. ERIFICATION ETHOD Completion of the steps above without any findings verifies proper security of the wing fold mecha- nism. ICON A5 / MAINTENANCE MANUAL CHANGE C0...

  • Page 785: Icon Parachute System (Ips)

    Activation System Inspection..........19-33 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 786 Activation System Installation ..........19-34 ELATED NFORMATION "Condition and 100-Hour Inspection—Parachute" on page 3-18 ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 787 19.1 IPS Description The ICON Parachute System (IPS) is comprised of the parachute package, harness, extraction rocket, activation system, landing gear deployment mechanism and all 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.
  • Page 788 19-4 ICON PARACHUTE SYSTEM (IPS) / DIAGRAM/SCHEMATIC 19.2 Diagram/Schematic ICON A5 / MAINTENANCE MANUAL CHANGE C1...
  • Page 789 ICON PARACHUTE SYSTEM (IPS) / TROUBLESHOOTING 19-5 19.3 Troubleshooting 19.3.1 Basic Parachute Inspection Use the following tasks to inspect the parachute. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required...
  • Page 790 19-6 ICON PARACHUTE SYSTEM (IPS) / TROUBLESHOOTING tion handle). Compare color, brightness, and texture. Replace activation line if there is any variation between these two sections. Check security of the activation handle mounting plate. Visually inspect the activation handle for damage or abnormalities.
  • Page 791 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE 19-7 19.4 Parachute Package 19.4.1 Parachute Package Description The IPS parachute package is comprised of deployment bag, BRS 601 rocket lanyard and retaining straps. The entire package, 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.
  • Page 792 19-8 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 16—ICON Parachute System (IPS) Consumables None NSTRUCTIONS External Inspection Inspect the parachute egress area for any cracks or displacement of the bond between the fuselage shell and removable cover.
  • Page 793 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE 19-9 Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 16—ICON Parachute System (IPS) Consumables 05-02687 (WIRE, SAFETY, SST, .041) IPC Reference NSTRUCTIONS Install the detent pin with the “REMOVE BEFORE FLIGHT”...
  • Page 794 19-10 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Cockpit Panels Removal and Installation" on page 3-36 19.4.4.2 Parachute Installation Use the following tasks to install the parachute package.
  • Page 795 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE 19-11 FIGURE 19-2 SECURING PARACHUTE DEPLOYMENT BAG The packed parachute is sent from the BRS facilities as presented in , with pin tether and/or curved release pins install a secure in its grommet and loop. If release pin tether and/or curved release pins have been removed during installation, they will need to be reinstalled and secured.
  • Page 796 19-12 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE FIGURE 19-4 KNOT SECURING RELEASE PIN Release pins are installed by BRS prior to delivery. NOTE Pull the flap on the left side to cover the rocket collar line and the incremental harness and secure ®...
  • Page 797 ICON PARACHUTE SYSTEM (IPS) / PARACHUTE PACKAGE 19-13 ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Cockpit Panels Removal and Installation" on page 3-36 "Harness Installation" on page 19-15 CHANGE C1 ICON A5 / MAINTENANCE MANUAL...
  • Page 798 19-14 ICON PARACHUTE SYSTEM (IPS) / HARNESS 19.5 Harness 19.5.1 Harness Description The IPS harness system includes the FWD and AFT Kevlar 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.
  • Page 799 ICON PARACHUTE SYSTEM (IPS) / HARNESS 19-15 Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required None Aircraft System and Number 16—ICON Parachute System (IPS) Consumables None NSTRUCTIONS Check for harness and riser entanglement and obstruction at all locations.
  • Page 800 19-16 ICON PARACHUTE SYSTEM (IPS) / HARNESS Task Specific Training Required Special Tools Required None Parts Required 008007-01 (Assy., Packed Parachute, A5) 014105-01 (Collar Assy., Pickup, Short Support) 005061-01 (Link, Quick, 1/2”, French SS) 001432-01 (Retaining Strap, A5) 007596-22 (Bridle, Kevlar, “A-C” End, Compact Tang) 007596-23 (Bridle, Kevlar, “A-C”...
  • Page 801 ICON PARACHUTE SYSTEM (IPS) / HARNESS 19-17 FIGURE 19-7 “A” END OF HARNESS ATTACHMENT POINT (STARBOARD REAR) Attach the “A” end of the forward harness to the forward attachment bracket on the STAR- BOARD side of the aircraft with the tie off pin and retaining ring.
  • Page 802 19-18 ICON PARACHUTE SYSTEM (IPS) / HARNESS FIGURE 19-10 HARNESS ROUTING, AFT, STARBOARD HARNESS TO PARACHUTE BAY Route 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 parachute bay.
  • Page 803 ICON PARACHUTE SYSTEM (IPS) / HARNESS 19-19 FIGURE 19-12 FORWARD STARBOARD HARNESS MOUNT LOCATIONS Install packed parachute assembly (Item 4) into parachute bay. Pin Release Tether and Retaining straps are shown below, attached to deployment bag. Rocket collar and lanyards can also be seen.
  • Page 804 Insert the harness package into the space between parachute and parachute cover. Three harnesses will be “S” folded into space AFT of the parachute bag in the ICON parachute bay and placed in the bay as a unite tied together with (2) two, 10.75” cable ties.
  • Page 805 ICON PARACHUTE SYSTEM (IPS) / HARNESS 19-21 FIGURE 19-15 HARNESS INSTALLATION: “S”-FOLD AND TIE WRAP When installing the parachute bag into the compartment, use care NOTE to be sure that bridles are neatly “S” folded and will be free from restrictions during recovery system deployment.
  • Page 806 19-22 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET 19.6 Extraction 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-powered solid fuel rocket deploys the parachute and harness system.
  • Page 807 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET 19-23 19.6.3 Inspection Instructions 19.6.3.1 Extraction Rocket Inspection Use the following tasks to inspect the extraction rocket system. NFORMATION Type of Maintenance Line Level of Certification LSA-RM Task Specific Training Required Special Tools Required...
  • Page 808 19-24 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Cockpit Panels Removal and Installation" on page 3-36 19.6.4 Maintenance Instructions 19.6.4.1 Extraction Rocket Removal Use the following tasks to remove the extraction rocket system.
  • Page 809 Mount the rocket pedestal with the rocket into the rocket bay. Secure the BRS 601 rocket assembly to ICON’s rocket mounting bracket using two of the BRS provided 1/4”-20 x3/4 Button HD Cap SS fasteners. Ensure that LOCTITE Blue 242 threadlocker is used to lock the fasteners in place.
  • Page 810 FIGURE 19-16 SECURE ROCKET TO ICON A5 ROCKET MOUNT BRACKET Fasten the rocket mount into the proper location in the ICON A5. Four AN3 bolts secure the rocket mount to the starboard center root rib. FIGURE 19-17...
  • Page 811 The rocket lanyard is already attached to the deployment bag at BRS Aerospace. The rocket lanyard will need to be routed and attached to the BRS 601 rocket in the ICON A5 rocket bay. Once the required length of lanyard is determined, the remaining length should be “looped” and secured with the small cable ties supplied.
  • Page 812 19-28 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET FIGURE 19-20 INCREMENTAL HARNESS TO DEPLOYMENT BAG STRAP ® All items are secured under the left side flap of the deployment bag, using the installed Velcro fasteners at the top side of the deployment bag.
  • Page 813 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET 19-29 Confirm that the safety pin and flag are installed in the activation WARNING handle before continuing to rocket installation section. FIGURE 19-22 SECURING ROCKET COLLAR TO BRS 601 ROCKET TUBE ERIFICATION ETHOD The procedure was completed when the component has been installed and the safety pin and flag are installed on the activation handle.
  • Page 814 19-30 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET 04035-01 (Screw, 10-24 x 5/8” S.S.) 04055-01 (Washer, Ext. Tooth, #10 S.S) 017004-01 (Screw, 10-24 x 3/8” PH) 005033-01 (Plug, Non-Threaded, 1/2”) Aircraft System and Number 16—ICON Parachute System (IPS) Consumables ®...
  • Page 815 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET 19-31 FIGURE 19-24 CHECKING CABLE LOOP SECURITY Pulling too hard can cause the extraction rocket to fire. WARNING 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.
  • Page 816 19-32 ICON PARACHUTE SYSTEM (IPS) / EXTRACTION ROCKET FIGURE 19-26 ACCESS HOLE PLUG ERIFICATION ETHOD The procedure is complete when the rocket has been successfully armed and all components are secure. ELATED NFORMATION "Removal and Installation of Inspection Panels and Fairings" on page 3-34 "Cockpit Panels Removal and Installation"...
  • Page 817 ICON PARACHUTE SYSTEM (IPS) / ACTIVATION SYSTEM 19-33 19.7 Activation System 19.7.1 Activation System Description The IPS activation system is a mechanical cockpit activation system used to initiate the recovery system. The system consists of a cockpit handle, an enclosed activation cable that connects cockpit handle to the extraction rocket ignition.
  • Page 818 19-34 ICON PARACHUTE SYSTEM (IPS) / ACTIVATION SYSTEM Special Tools Required None Parts Required None Aircraft System and Number 16—ICON Parachute System (IPS) Consumables None NSTRUCTIONS Inspect activation cable line from the activation handle to the rocket for evidence of cracking, kinking, or chaffing.
  • Page 819 ICON PARACHUTE SYSTEM (IPS) / ACTIVATION SYSTEM 19-35 Level of Certification LSA-RM Task Specific Training Required Special Tools Required None Parts Required ICA009677 (FLAG, REMOVE BEFORE FLIGHT, RED CLOTH, 1.5X4.5) MS21043-4 (NUT, SLFKG, RDC HEX, CRES, .250-28) TY24MX_01 (CABLE-TIE, NYLON 6-6, 30LB, 5.50, TY-RAP .5 DIA)
  • Page 820 19-36 ICON PARACHUTE SYSTEM (IPS) / ACTIVATION SYSTEM FIGURE 19-28 SECURING ACTIVATION CABLE ROUTING The activation cable can be secured using cable ties. NOTE Route the activation assembly. Apply the second cable tie to secure the activation housing to the cable tie mount.
  • Page 821 ICON PARACHUTE SYSTEM (IPS) / ACTIVATION SYSTEM 19-37 FIGURE 19-30 SECURING ACTIVATION CABLE ROUTING The activation cable can be secured using cable ties or any other NOTE suitable method. Activation cable routed to rocket mount position. After securing the activation cable in the previous step, the activation cable will be in position to connect to the launch tube cone at the rocket mounting point.
  • Page 822 19-38 ICON PARACHUTE SYSTEM (IPS) / ACTIVATION SYSTEM ICON A5 / MAINTENANCE MANUAL CHANGE C1...

  • Page 823: Structural Repair

    General Bonded Fastener Installation ......... . .20-5 CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 824 20.1 Description ICON Aircraft does not allow 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 the Major Repair and/or Alteration (MRA) process.
  • Page 825 LSA-RM Task Specific Training Required Specific Tools Required None Parts Required Many bonded fasteners are used in the A5. These include: CB3000 Large Metallic Base Stud CB3021 Reverse-Mounted Stud CB3033 Reverse-Mounted Standoff CB4000 Large Composite Base Stud CB4020 Composite Right-Angle Cable Tie Mount...
  • Page 826 None Read these repair instructions in their entirety before starting. Any questions or uncertainties regarding interpretation of these instructions shall be forwarded to ICON Owner Support before any work is done. All substrate materials must be protected from temperatures exceeding 200°F during the application of heat to soften the adhesive material attaching the fastener.
  • Page 827 LSA-RM Task Specific Training Required Specific Tools Required None Parts Required Many bonded fasteners are used in the A5. These include: CB3000 Large Metallic Base Stud CB3021 Reverse-Mounted Stud CB3033 Reverse-Mounted Standoff CB4000 Large Composite Base Stud CB4020 Composite Right-Angle Cable Tie Mount...
  • Page 828 Consumables None The new fastener must be selected and located in accordance with the appropriate supporting docu- mentation. Contact ICON Owner Support if lacking definition of what fastener to use or where to place NSTRUCTIONS ® Prepare and clean the substrate in the area to be bonded in accordance with the Click Bond CBPS-206 Rev.

  • Page 829: Painting And Coatings

    Description..............21-2 CHANGE C0 ICON A5 / MAINTENANCE MANUAL...
  • Page 830 Any alteration to the paint or paint scheme of the ICON A5 is not permitted at this time. Repairs to the paint or coatings must be coordi- nated with ICON through the MRA process or handled by ICON directly.
  • Page 831 Manual Improvement or Correction Form ........22-6 CHANGE C0 ICON A5 / MAINTENANCE MANUAL...

  • Page 832: Feedback Forms

    FEEDBACK FORMS / FEEDBACK FORMS 22.1 Feedback Forms The following forms are for the aircraft owner or maintainer to provide notification to ICON Aircraft about: Issues and anomalies identified during the operation or maintenance of the aircraft or in the content of this manual.
  • Page 833 To notify ICON Aircraft of 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 via the following channels: ICON Aircraft, Inc.
  • Page 834 SERIAL NUMBER: REGISTRATION NUMBER: ENGINE TACH TIME: TOTAL TIME: DESCRIPTION OF SAFETY OF FLIGHT ISSUE OR SIGNIFICANT SERVICE DIFFICULTY: Please forward this form and any supporting information to ICON Owner Support: ICON Aircraft 2141 ICON Way Vacaville, CA 95688 (855) FLY-ICON support@iconaircraft.com...
  • Page 835 FEEDBACK FORMS / CONTINUED OPERATIONAL SAFETY REPORTING 22-5 22.2.2 Change of Address/Ownership Form – www.iconaircraft.com 2141 ICON Way, Vacaville, CA 95688 - Tel: 707.564.4000 CHANGE OF ADDRESS/OWNERSHIP FORM AIRCRAFT INFORMATION MODEL: SERIAL NUMBER: REGISTRATION NUMBER: OLD INFORMATION NAME: First Last...
  • Page 836 TOTAL TIME: DESCRIPTION OF IMPROVEMENT OR CORRECTION: Maintenance Manual Pilot’s Operating Handbook (POH) Other SIGNATURE DATE Please forward this form and any supporting information to ICON Owner Support at: ICON Aircraft 2141 ICON Way Vacaville, CA 95688 (855) FLY-ICON support@iconaircraft.com ICA009722-...

Table of Contents

Save PDF