MAINTENANCE MANUAL

C4 28 May 2020 1, 2, 3, 4, 6,7, 8, 9, 10,11, 12, 13, 14, 16, 17, 18, 22 ICON Aircraft C5 01 July 2021 1, 2, 3, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 ICON Aircraft REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-3 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • Updated Revision information • Updated Manual Revisions information Chapter 2 • General Editorial Changes, Updated Related Information and Cross References • Updated Introduction • Updated the Organization and Structure description to reflect changes to Task Information throughout document • Updated Maintenance Levels of Certification • Updated Heavy Maintenance information • Updated Level of Certification Hierarchy • Added Aircraft Serial Number to the Maintenance Terminology and Abbreviations • Updated the Safety Directives and COS information • Updated the Logbook Instructions • Updated the Special Tools information Chapter 3 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Condition and 100-Hour Inspection—Aircraft Identification and General table • Updated Condition and 100-Hour Inspection—Landing Gear table • Updated Condition and 100-Hour Inspection—Aft Fuselage and Empennage table • Updated Empty Weight and CG Measurement • Updated Removal and Installation of Inspection Panels and Fairings • Added Baggage Sidewall Panel Removal and Installation for ASN 00021+ • Added Autopilot (AP) Control Panel Removal and Installation instructions Chapter 4 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion 1-4 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • Updated Rinse After Salt Water Operations table Chapter 6 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Added System Wiring Diagrams for Garmin G3X Autopilot • Added Remove and Install Connector/Terminal instructions • Updated Battery Description • Updated Battery Diagnostic • Updated Remove and Install instructions for original battery configuration to include new battery option • Added Remove and Install instructions for new battery configuration • Updated Bilge Pump Description • Updated Installation of Wing Tip Lights instructions • Updated Remove Landing and Taxi Lights instructions Chapter 7 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Heater Fan and Core Removal task • Updated Heater Fan and Core Installation for ASN 00001-00109 • Added Heater Fan and Core Installation for ASN 110+ Chapter 8 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Right Instrument Panel Top Panel Installation instructions • Added Radio Stack Removal and Installation instructions for ASN 00139+ REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-5 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • Added Garmin G3X and Autopilot Bezel Removal and Installation instructions for ASN 00139+ • Added Remove and Install IP Top Chapter 9 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated verification method of Inspect Rudder Pedal Rigging • Updated Install Flap Actuator • Updated Re-Rigging Rudder Pedals Chapter 10 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Install Fuel Tank instructions Chapter 11 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Separated Removal and Installation of Seawings™ Platform Tip instructions into Remove and Install instructions • Added Install Seawings™ Platform Tip instructions • Updated Repair of Seawings™ Tip Attach Pins and Bushings instructions • Updated Installation of Water Rudder Cable instructions Chapter 12 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Elevator Pushrod Installation instructions 1-6 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • Updated Air Rudder Installation instructions • Updated Measure Horizontal Tail Tip Anti Rotation Pin Wear instructions Chapter 13 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Annunciator Panel Diagnostic instructions • Added Remove and Install Microphone and Headphone Jack instructions • Updated ELT Inspection and Function Check • Updated image in Cockpit Instrument Markings • Added Garmin G3X Touch™ section • Added Remove and Install OAT Sensor • Added Remove and Install Pitch Servo (Autopilot Configuration) • Added Remove and Install Roll Servo (Autopilot Configuration) • Added Remove and Install Roll Servo to Bracket • Added Remove and Install ADAHRS • Added Remove and Install EIS • Added Remove and Install Magnetometer • Added Instructions for setting the Magnetometer level • Added Remove and Install G3X Display • Added Remove and Install IP Center Spine • Added Disconnect and Connect Garmin G3X and Autopilot Navigation System • Added Remove and Install ADS Antenna for ASN 00139+ • Added Remove and Install ADS-B GPS Receiver for ASN 00139+ • Updated description of Pitot-Static-AOA Leak Test Procedures • Added Remove and Install IP Center Spine • Added Remove and Install Main Wire Harness • Added Make Electrical Connections • Added Cut Tubing to Length REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-7 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • Added Disconnect and Connect Pitot Line • Added Disconnect and Connect Static Line • Added Disconnect and Connect High Pressure AOA Line • Added Disconnect and Connect Low Pressure AOA Line • Updated measurement in step 2 of Install Fuel Level Sensor Chapter 14 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated Landing Gear Description • Updated Rudder Pedal Connector Lines Replacement torque information • Updated Forward Lines Replacement torque information • Updated Aft Lines Replacement torque information • Updated Main Landing Gear (MLG) Installation instructions • Updated Parking Brake Valve Assembly and Installation Procedure Chapter 15 • Added Garmin G3X Touch™ with Autopilot fuse placard Chapter 16 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Updated the Engine Description • Added Extract ECU Data • Updated Oil System Description • Updated Level of Certification on A5 Specific Oil Change Procedures • Added Adjust Propeller Pitch Chapter 17 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task 1-8 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion Chapter 18 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion • Added Remove and install Double Lock Wing Hang Assembly Chapter 19 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion Chapter 20 • General Editorial Changes, Updated Related Information and Cross References • Added Safety Equipment information to Task Information for each task • Added Applicable Aircraft Serial Number to any task that did not already include the informa- tion 1.1.2 Issue C4 Multiple Chapters • Added Aircraft Serial Numbers (ASN) to multiple sections Chapter 2 • Updated Introduction • Changed references of “Service Notification” with “Service Letter” • Added Aircraft Serial Number Effectivity • Added Horizontal Tail (HT) to Terminology and Abbreviations • Updated Safety Directives and Continued Operational Safety • Updated Logbook Instructions • Updated Sources to Purchase Parts • Updated Special Tools list • Updated Locking Nuts information in Fasteners REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-9 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 Chapter 3 • Updated Condition Inspections and 100-Hour Inspections Special Tools • Updated Interval Maintenance-Operational Hours section • Updated Condition and 100-Hour Inspection-Aircraft Identification and General table • Updated Condition and 100-Hour Inspection-Wings table • Updated Condition and 100-Hour Inspection-Forward Fuselage and Hull table • Updated Condition and 100-Hour Inspection-Parachute table • Updated Condition and 100-Hour Inspection-Aft Fuselage and Empennage table • Updated Condition and 100-Hour Inspection-Landing Gear table • Updated Condition and 100-Hour Inspection-Engine and Propeller table • Added MRAs to general 100Hr Inspection • Moved Fuel Level Sensor Replacement to Chapter 6 • Updated Weight and CG Measurement While on Gear procedure • Updated Notifications to Service Letters throughout • Updated Install Cockpit Floor Board procedure • Updated Remove and Install procedures for Cockpit Sidewall Panel • Updated Remove Seat Back procedure • Updated Manual Tap Test Chapter 4 • Updated NA to Aircraft System and Number section of Rinse procedures Chapter 6 • Updated Landing Gear Electrical Wiring Diagram • Moved and updated Fuel Level Sensor Replacement from Chapter 3 and updated to Remove Fuel Level Sensor and Install Fuel Level Sensor • Updated part numbers of Wing Tip Lights • Added new Remove and Install procedures for Low Fuel Level Sensor Chapter 7 • Updated Verification Method of Heater Fan and Core Installation Chapter 8 • Updated Left Instrument Panel Top Panel Removal and Installation procedures 1-10 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 Chapter 9 • Updated Inspect Roll Rigging procedure • Updated Remove Roll Cables Images procedure • Updated Inspect Pitch Cable Tension procedure • Updated Rigging Pitch Control procedure • Updated Install Pitch Trim Actuator part number • Updated Rigging Flap Controls part number Chapter 10 • Updated Clean Coarse Fuel Filter procedure for ASN 21-109 • Updated Remove Fine Fuel Filter procedure • Updated Sump Fuel Tank procedure • Added new Fuel System section and update name of Remove/Install Fuel Tank • Added new Remove and Install Fuel Pump procedures for ASN 21+ • Added new Remove and Install Fuel Shutoff Valve procedures for ASN 1+ • Added new Remove and Install Lower Fuel Check Valve procedures for ASN 21+ • Added new Remove and Install Upper Fuel Check Valve procedures for ASN 1+ Chapter 11 • Updated part numbers in Seawings™ Platform Tip Removal and Installation • Updated part numbers in Repair of Seawings™ Tip Attach Pins and Bushings Chapter 12 • Updated Removal and Installation procedures for Air Rudder • Updated Elevator Pushrod Removal • Updated Horizontal Tail Removal • Updated Horizontal Tail Installation Chapter 13 • Updated part numbers in Replace Instrument Panel Gauge • Add new ADS-B Removal and Installation procedures • Add new Removal and Installation procedures for ADS-B GPS Receiver • Updated Overhead Console Component Replacement • Updated Replace Instrument Panel Gauge REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-11 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • Updated Install Instrument Cluster • Updated DAC Memor Unit Re-Installation • Removed Verify DAC Software Version as this should only be done by ICON • Updated Install Fuel Pressure Sensor part number information • Add new Remove and Install Low Fuel Level Sensor tasks • Updated A5 Specific Oil Change Procedures • Updated Spinner Dome Chapter 14 • Updated Nose Wheel Tire Leak procedure • Updated Check Landing Gear Retracted Position procedure • Updated Main Landing Gear Inspection procedure • Updated Landing Gear Actuator Limit Switch Adjustment Procedure and added procedure for ASN 110+ • Overhauled Nose Landing Gear Rigging and Check procedures Chapter 16 • Updated Special Tool information in Engine Installation and Engine Removal procedures • Updated Exhaust System Diagram/Schematic description • Added Install and Remove procedures for Exhaust System ASN 110+ • Updated Grease Coil Pack Connection procedure • Updated Remove and Install procedures for Coolant Radiator • Added new Remove and Install procedures for Oil Cooler and Thermostat ASN 1-20 • Added new Remove and Install procedures for Oil Cooler and Thermostat ASN 21+ Chapter 17 • Add new Remove and Install procedures for EPDM Foam • Updated Install Left Wing procedure • Updated Wing Hang Pin Replacement procedure Chapter 18 • Updated Inspect Wing Pins procedure Chapter 22 • Updated Continued Operational Safety Reporting section 1-12 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 1.1.3 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 • Updated Empty Weight and CG Measurement Chapter 4 • Updated Wheels and Brakes Chapter 6 • Added Landing & Taxi Lights Maintenance Instructions • Added Fuel Level Sensor Description • Updated Inspect, Repair, and Secure Wiring Harness with Signs of Chafing • Updated Install Fuel Pressure Sensor • Moved Grease Coil Pack Connections to Chapter 16 • Added Landing and Taxi Lights section • Updated Battery Description • Updated Replace Coarse Fuel Filter • Move Bilge Pump from Chapter 7 • Updated Charge Battery Chapter 7 • Move Bilge Pump section to Chapter 7 Chapter 8 • Updated Center Console Bucket Removal • Updated Throttle Handle and Bezel • Updated GPS Mount and Radio Stack Bezel • Added Instrument Panel Center Spine Removal and Installation Chapter 9 • Updated Remove Flap Actuator REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-13 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • 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 • Added Yaw Controls Description • Added Yaw Controls Diagram • Updated Rigging Yaw Controls Chapter 10 • Updated Pump Usable Fuel from Fuel Tank • Added Fuel Pressure Diagnostic • Added coarse Fuel Filter Description and Schematic • Added Clean Coarse Fuel Filter (MY18+) • Updated Clean Coarse Fuel Filter (MY17 Only) • Renamed Fuel Bladder (MY17 Only) sections • Updated Fuel Bladder and Fuel Tank sections • Added Remove Fine Fuel Filter • Added Install Fine Fuel Filter Chapter 12 • Added Horizontal Tail Tip Lock Switches section Chapter 13 • Added DAC Software Version section • Updated the Instruments and Avionics Description • Added Central Stack Instruments section • Added ELT Transponder and Transmitter Replacement • Added Pitot-Static-Angle of Attack (AOA) maintenance tasks Chapter 14 • Updated Nose Landing Gear (NLG) Wheel Removal 1-14 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • Updated Main Landing Gear (MLG) Removal • Added Nose Wheel Tire Leak • 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 • Updated ELT Remote Switch placard Chapter 16 • Moved Grease Coil Pack Connections from Chapter 6 • Updated Install Exhaust System • Updated Install Fuse Box and Regulators • Added Propeller Schematic • Added Install Oil Tank • 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 • Added ECU Troubleshooting Chapter 17 • Updated Wing Lock Switch Mounting Plate Installation • Updated Wing Lock Switch Mounting Plate Removal 1.1.4 Issue C2 Chapter 2 • Updated Disposable Replacement Part list • Updated the nose gear tire size in Tire Inflation Pressures REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-15 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 Chapter 4 • Updated the nose gear tire size in Wheels and Brakes Chapter 9 • Added Pitch Controls Section • Updated Inspect Pitch Cable Tension • Renamed Elevator Rigging to Inspect Pitch Rigging 1.1.5 Issue C1 Chapter 2 • Updated Special Tools list Chapter 3 • Updated Condition and 100-Hour Inspection-Parachute list • Updated Condition and 100-Hour Inspection-Forward Fuselage and Hull • Updated Condition and 100-Hour Inspection-AFT Fuselage and Empennage • Updated Condition and 100-Hour Inspection-Fuel Systems • Updated Condition and 100-Hour Inspection-Engine and Propeller • Updated Condition and 100-Hour Inspection-Avionics and Electronics Chapter 6 • Updated chapter description • Added Grease Coil Pack Connections task • Added Inspect, Repair, and Secure Wiring Harness with Signs of Chafing • Added Wing Tip Lights description • Added Remove Wing Tip Lights • Added Install Wing Tip Lights • Added Dome Light Switch description • Added Remove Dome Light Switch • Added Install Dome Light Switch • Added Battery description • Added Charge Battery task • Added Battery Diagnostic task 1-16 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • 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 • Added Inspect Control Cables (Acceptable Conditions) • Updated Aileron Cable Tension to Inspect Roll Cable Tension • Updated Aileron Controls to Roll Controls • Updated Check Aileron Rigging to Inspect Roll Rigging • Updated Aileron Rigging to Rigging Roll Controls • Added Remove Roll Cables • Added Install Roll Cables • Added Roll Trim Tab description • Added Roll Trim Tab diagram • Added Remove Roll Trim Tab task • Added Install Roll Trim Tab task • Added Determine Roll Trim Tab Length task • Added Pitch Controls description • Added Pitch Controls diagram • Added Pitch Trim Actuator description • Added Pitch Trim Actuator diagram • Added Pitch Trim Tab description • Added Pitch Trim Tab schematic Chapter 10 • Added Remove Fuel Tank • Added Install Fuel Tank Chapter 11 • Moved Rudder Rigging content to Chapter 9 and renamed Rudder to yaw REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-17 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • Moved Elevator Rigging content to Chapter 9 and renamed Elevator to Pitch • 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 • Added ELT diagram • Added VHF Comm Antenna description • Added VHF Comm Antenna diagram • Added Annunciator Panel Description • Added Annunciator Panel Diagnostic • Updated Pitot-Static-AOA Leak task Chapter 14 • Updated Check Landing Gear Retracted Position task • Added Landing Gear Actuator Fuse Blown task • Added Landing Gear Excessive Friction Check task • Added Parking Brake Valve Replacement Procedure • Updated step five of MLG Wheel and Axle Installation • Updated step 2 of MLG Actuator Removal • Updated Replace Nose Landing Gear Actuator task • Updated name of Aft Nose Landing Gear to Aft Nose Landing Gear Door • Added MLG Rigging and Rigging Check with Landing Gear Up • Added Landing Gear description • Added Landing Gear diagram • Updated Check Landing Gear Extended Position Chapter 16 • Updated Exhaust System • Updated Engine description • Updated Install Engine 1-18 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • Updated Remove Engine • 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 • Moved Remove Engine Cowlings from chapter three • Added Install Engine Cowlings • Renamed Throttle Control Proper Travel and Security to Install Throttle Control Proper Travel and Security Chapter 17 • Moved Flap Actuator content to Chapter 9 • Moved Flap Gas Strut content to Chapter 9 • Flap Hinge Repair procedure moved from Chapter 11 Chapter 19 • Added IPS Description • Added Parachute Package Removal • Added Parachute Package Installation • Added Harness Installation • Added Extraction Rocket Removal • Added Extraction Rocket Installation • Added Arming Extraction Rocket task • Added Activation System Installation task • Updated Activation System Installation 1.1.6 Issue C All Chapters • Complete layout overhaul Chapter 2 • Update to the logbook instructions REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-19 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • 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) Chapter 4 • Updated task specific training in Use of VHB Tape for Installations and Repairs Chapter 7 • References to torque stripe deleted from manual Chapter 8 • Added Center Console Bucket procedure • Added Throttle Handle and Bezel procedure Chapter 9 • Added Measure Pitch Trim Tab Wear procedure • Added Aileron Cable Tension Check • Added Elevator Cable Tension Check • Added Rudder Cable Tension Check Chapter 11 • 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 • Wheel and Brake System Maintenance updated • Update task specific training in Nose Landing Gear Actuator Replacement Chapter 16 • Updated Engine Mount Installation and Removal • Added Spinner Dome removal and installation 1-20 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 • Updated Engine Coolant Replacement Chapter 17 • Replace wording of “wing lock cross pins” with “wing locking pins” • Updated Flap Hinge Repair • Updated task specific training in Aileron Cable Maintenance and Tensioning • Change title of Aileron Cable Maintenance and Tensioning to Aileron Rigging Chapter 19 • Changed Complete Aircraft Parachute to ICON Parachute System (IPS) REVISIONS / LIST OF EFFECTIVE CHAPTERS 1-21 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 1.2 List of Effective Chapters The table below shows the current effective chapters and dates in this revision of the handbook (see previous section). The applicable maintenance manual revision is listed below the table for reference. Chapter Change Date 1. REVISIONS C5 01 July 2021 2. GENERAL C5 01 July 2021 3. INSPECTIONS C4 01 July 2021 4. STRUCTURES C4 01 July 2021 5. DOORS AND WINDOWS C0 20 April 2018 6. ELECTRICAL SYSTEM C4 01 July 2021 7. ENVIRONMENTAL CONTROL (UTILITY SYSTEMS) C3 01 July 2021 8. EQUIPMENT AND FURNISHINGS C3 01 July 2021 9. FLIGHT CONTROLS C5 01 July 2021 10. FUEL SYSTEM C4 01 July 2021 11. FUSELAGE AND VERTICAL TAIL C3 01 July 2021 12. HORIZONTAL TAIL C3 01 July 2021 13. INSTRUMENTS (AND AVIONICS) C4 01 July 2021 14. LANDING GEAR C4 01 July 2021 15. PLACARDS AND MARKINGS C2 01 July 2021 16. PROPULSION C4 01 July 2021 17. WING C4 01 July 2021 18. WING FOLD MECHANISM C2 01 July 2021 19. ICON PARACHUTE SYSTEM (IPS) C2 01 July 2021 1-22 REVISIONS / LIST OF EFFECTIVE CHAPTERS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 Applicable to Maintenance Manual Revision: Issue C5 RELATED I NFORMATION: "Manual Revisions" on page 1-23 20. STRUCTURAL REPAIR C1 01 July 2021 21. PAINTING AND COATINGS C0 20 April 2018 22. FEEDBACK FORMS C1 28 May 2020 Chapter Change Date REVISIONS / MANUAL REVISIONS 1-23 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 1.3 Manual Revisions This MM utilizes chapter-level revision control. Each page of the manual contains a revision indication in the lower, inside corner. Revision indicators are consistent throughout an entire chapter, but may vary from chapter to chapter. A major release of the manual is called an “Issue”. The issue letter and its effective date are listed on the title page of the manual using a letter code; for example, “Issue A”. Updates and changes to the manual are called “Revisions” and are designated using an issue prefix followed by a number; for example, “Revision A2” is the second revision of “Issue A”. These revisions are listed on the Record of Manual/Handbook Revisions page near the front of the handbook. Owners are responsible for keeping this page updated when handbook revisions are issued by ICON. Updates and changes to chapters of the manual are called “Changes” and are designated using the issue prefix followed by a number; for example, “Change A0” is the original release of a chapter in Issue A and “Change B3” is the third revision of a chapter in Issue B of the entire manual. The “List of Effec- tive Chapters” near the front of the manual documents the applicable chapter “Changes” associated with a given manual revision. Updates and changes to the manual are defined as corrections or changes to the content of the manual. These changes are indicated by a change bar. Change bars are not placed on small editorial changes like the correction of spelling errors or typos when the substance of the content is not affected or reference information related to the content like Related Information and cross references. Revisions to this Maintenance Manual will be distributed to all owners of relevant aircraft registered with ICON. Distribution will be of the entire manual with any necessary instructions. Revisions should be examined immediately upon receipt. 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. RELATED I NFORMATION: "Record of Maintenance Manual Revisions" on page 1-2 "List of Effective Chapters" on page 1-21 1-24 REVISIONS / MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 1 Chapter 2 GENERAL / 2-1 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 GENERAL Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 General Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Maintenance Terminology and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Organization and Structure of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Maintenance System for Light Sport Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Line Maintenance, Repairs, and Alterations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Heavy Maintenance, Repairs, and Alterations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Maintenance Levels of Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Task-Specific Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Minimum Levels of Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Level of Certification Hierarchy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Major Repairs and Alterations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Safety Directives and Continued Operational Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Instructions for Reporting Safety of Flight Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Logbook Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Sources to Purchase Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Disposable Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 Weight and Balance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 Tire Inflation Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Approved Engine Oils and Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Approved Fuel Grades and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Approved Engine Coolant Grades and Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Flat Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Lock Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 2-2 GENERAL / ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 2 Locking Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 Castle Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Clevis Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Cotter Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Threaded Taper Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Safety Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Turnbuckles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Threadlocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Fabricated Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32 Torque Procedure and Fastener Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32 Transportation by Trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 Aircraft Serial Number Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 GENERAL / INTRODUCTION 2-3 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.1 Introduction This maintenance manual provides the standard maintenance and inspection procedures for the A5. Repairs, alterations, and maintenance tasks included within this manual are considered minor. Task instructions applicability will be indicated by serial numbers. (See “Aircraft Serial Number Effectivity” on page 2-35.) 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. The minimum levels of certification to perform any minor task are also listed in this manual. NOTE: The information in this manual is the best available at the time of publication. As modifications for product improvement may have occurred, your aircraft could have a different configuration than described. Contact ICON Aircraft if your hardware does not match the instructions in this manual. This manual was developed in compliance with the ASTM standard F2483-18e1, Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft. RELATED I NFORMATION: "Aircraft Serial Number Effectivity" on page 2-35 2-4 GENERAL / SYMBOLS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 2 2.2 Symbols This handbook uses the following symbols and definitions to emphasize important information. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation or instruction which, if not avoided or followed, may result in minor or moderate injury or severely damage the aircraft. NOTE: Indicates supplementary information that may be needed to fully complete or understand an instruction. GENERAL / GENERAL SAFETY INFORMATION 2-5 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.3 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. Material Safety Data Sheets (MSDS) for chemicals specified in this manual are avail- able online. Maintenance personnel are responsible for keeping themselves informed of workplace hazards, participating in training, following all applicable safety policies and procedures, and promptly reporting hazards and accidents to their supervisor. Maintenance personnel should pay particular attention to the ergonomic set up of work stations, desks, computers and other daily use equipment. If you spend long periods of time using a computer, other office equipment, or perform any type of repetitive motion during the course of your work, be sure to change your position at least once every half hour to avoid eye strain, back and neck strain, and repetitive injuries such as carpal tunnel. Remember to always use proper lifting techniques which may include: using leg muscles rather than back muscles, team lifts and inspect items to be moved for protruding nails, slivers, sharp edges, etc., before handling. 2-6 GENERAL / MAINTENANCE TERMINOLOGY AND ABBREVIATIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 2 2.4 Maintenance Terminology and Abbreviations Condition Inspection A detailed inspection accomplished once in the preceding 12 calendar months on an LSA in accordance with instructions provided in the maintenance manual supplied with the aircraft. The purpose of the inspection is to look for any wear, corrosion, or damage that would cause an aircraft to not be in a condition for safe operation. A&P Airframe and powerplant mechanic as defined by 14 CFR Part 65 in the U.S. or equivalent certi- fication in other countries. Heavy Maintenance Any maintenance, inspection, repair, or alteration a manufacturer has specified in the mainte- nance manual that requires specialized training, equipment, or facilities. Line Maintenance Any repair, maintenance, scheduled checks, servicing, inspections, or alterations not considered heavy maintenance that is approved by the manufacturer and is specified in the manufacturer’s maintenance manual. LSA Repairman Maintenance (LSA-RM) U.S. FAA-certificated repairman (light sport aircraft) with a maintenance rating as defined by 14 CFR Part 65 (or equivalent rating issued by another civil aviation authority), who is authorized to perform line maintenance on aircraft certificated as special LSA aircraft. Authorized to perform the condition and 100-hour inspections on an LSA. Maintenance Manual (MM) A manual provided by an LSA manufacturer or supplier that specifies all maintenance, repairs, and alterations authorized by the manufacturer. Major Repair, Alteration, or Maintenance (MRA) Any repair, alteration, or maintenance for which instructions to complete the task are excluded from the maintenance manual supplied to the consumer. NOTE: Any major repairs, require prior coordination and approval from ICON Aircraft before commencing work. Minor Repair, Alteration, or Maintenance Any repair, alteration, or maintenance for which instructions to complete the task are included in the maintenance manual supplied to the consumer. Overhaul 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. GENERAL / MAINTENANCE TERMINOLOGY AND ABBREVIATIONS 2-7 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 Repair Facility Facility specifically authorized by the aircraft or component manufacturer to repair the product originally produced by that manufacturer. Voltage Standing Wave Ratio (VSWR) The measure of how efficiently radio-frequency power is transmitted from a power source, through a transmission line, into a load. 100-Hour Inspection Same as a condition inspection, except the interval of inspection is 100 hours of operation instead of once in the preceding 12 calendar months. This inspection is utilized when the LSA is flown 100 hours before the preceding 12 calendar months have passed from the last Condition or 100-Hour Inspection. AP Autopilot A&P Airframe and Powerplant ASN Aircraft Serial Number BRS Ballistic Recovery Systems CG Center of Gravity IPS ICON Parachute System COS Continued Operational Safety ECU Engine Control Unit EGT Exhaust Gas Temperature ELT Emergency Locater Transmitter HT Horizontal Tail INOP Inoperable EMS Engine Management System 2-8 GENERAL / MAINTENANCE TERMINOLOGY AND ABBREVIATIONS ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 2 LH Left Hand LSA Light Sport Aircraft LSA-RM Light Sport Aircraft—Repairman Maintenance MLG Main Landing Gear MM Maintenance Manual MRA Major Repair and/or Alteration NLG Nose Landing Gear PIM Parachute Installation Manual RF Radio Frequency RH Right Hand TED Trailing Edge Down TEL Trailing Edge Left TER Trailing Edge Right TEU Trailing Edge Up VSWR Voltage Standing Wave Ratio GENERAL / ORGANIZATION AND STRUCTURE OF THIS MANUAL 2-9 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.5 Organization and Structure of This Manual Understanding the organization and structure of this MM is key to properly using it. This General chapter describes helpful information and provides information about the maintenance system or framework within which the 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. The following chapters provide inspection, maintenance, repair, or alteration tasks developed for the A5 Structures, Doors and Windows, Electrical System, Environmental Control (Utility Systems), Equip- ment and Furnishings, Flight Controls, Fuel System, Fuselage and Vertical Tail, Horizontal Tail, Instru- ments (and Avionics), Landing Gear, Placards and Markings, Propulsion, Wing, Wing Fold Mechanism, ICON Parachute System, Structural Repair, and Paintings and Coatings. The Feedback Forms chapter provides additional reference information. Each task provided in this MM is structured using the following general format. Applicable Aircraft Serial Number Task is valid for all serial numbers unless otherwise specified. Type of Maintenance The specific type of maintenance (Line, Heavy, or Overhaul). Level of Certification This provides the qualifications of an individual who may complete the task (Owner/Pilot, LSA-RM, or A&P). Task-Specific Training Required Yes/No Special Tools Needed A list of any tools needed that are not included in a common mechanic’s toolbox. If there are none, then it will say ‘None’. Parts Needed Parts that will be needed to perform the task. If there are none, then it will say ‘None’. Task Instructions A list of steps or instructions to perform the task. Aircraft System and Number ICON Aircraft system name and number. Safety Equipment Any Personal Protective Equipment (PPE) needed to perform the task. Consumables A list of any consumables items needed to perform the task. If there are none, then it will say ‘None’. Verification Method 2-10 GENERAL / ORGANIZATION AND STRUCTURE OF THIS MANUAL ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 2 The means of inspecting or verifying that the task was accomplished properly. Following this task format, tasks may include a Related Information section which provides one or more references to other helpful tasks or reference material. RELATED I 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 GENERAL / MAINTENANCE SYSTEM FOR LIGHT SPORT AIRCRAFT 2-11 CHANGE C5 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.6 Maintenance System for Light Sport Aircraft 2.6.1 Introduction Most maintenance, inspection, repair, or alteration tasks described in this manual are considered line maintenance, and the authorizations to perform each individual task can be found in each individual task. 2.6.2 Line Maintenance, Repairs, and Alterations Line maintenance, repairs, and alterations may be performed by the holder of an LSA repairman certif- icate with either an inspection or maintenance rating or by an A&P mechanic. Some simpler tasks are authorized for completion by an Owner/Pilot. In these cases, the person performing the work must hold at least a Sport Pilot certificate. RELATED I NFORMATION: "Organization and Structure of This Manual" on page 2-9 2.6.3 Heavy Maintenance, Repairs, and Alterations Heavy maintenance, repairs, and alterations must be approved by a certified A&P mechanic or Part 145 repair station. RELATED I 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. See Overhaul Maintenance section for overhaul information in this manual. RELATED I NFORMATION: "Organization and Structure of This Manual" on page 2-9 "Condition and 100-Hour Inspection—Paperwork" on page 3-27 "Overhaul Maintenance" on page 3-8 2.6.5 Maintenance Levels of Certification The following section defines the minimum levels of maintenance personnel certification for the A5. Also defined is the hierarchy of those certification levels and task-specific training. 2-12 GENERAL / MAINTENANCE SYSTEM FOR LIGHT SPORT AIRCRAFT ICON A5 / MAINTENANCE MANUAL CHANGE C5 CHAPTER 2 RELATED I NFORMATION: "Organization and Structure of This Manual" on page 2-9 2.6.5.1 Task-Specific Training Task-specific training is specified for those tasks where specialized knowledge of the A5 is required in order to accomplish the task properly. 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. The levels are Owner/Pilot, LSA Repairman Maintenance (LSA-RM), or A&P mechanic. In addition to these levels of certification, any task may also require task-specific training. Owner/Pilot—Items that can be expected to be completed by a responsible owner who holds at least a Sport Pilot certificate but who has not received any specific authorized training. LSA Repairman Maintenance (LSA-RM)—Items that can be expected to be completed on a SLSA by a responsible individual, who holds an FAA repairman certificate (light sport aircraft) with a mainte- nance rating. A&P—Items that can be expected to be completed by a responsible individual who holds a mechanic certificate with airframe and/or powerplant rating. Task-Specific—Items that can be expected to be completed by a responsible individual who holds the required level of certification (Owner/Pilot, LSA-RM, A&P) and in addition has received task-specific training to perform the task. 2.6.5.3 Level of Certification Hierarchy Each task requires definition of a level of certification. There is, however, no inherent hierarchy between these levels. The following listing defines a hierarchy for the purposes of this A5 mainte- nance manual that gives the limitation of each level. • Owner/Pilot can perform only the tasks explicitly listed with the Owner/Pilot. • LSA-RM can perform tasks that list any of Owner/Pilot or LSA-RM. • A&P can perform tasks that list any of Owner/Pilot, LSA-RM, or A&P. • For any of the above, if a task indicates ‘Yes’ for the task-specific requirement, then the training specified is required in addition to the level of certification (e.g. LSA-RM + task-specific).