MODEL A5 MAINTENANCE MANUAL

• 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 • 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 1-4 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 1 • 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 • 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 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-5 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • 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 1.1.2 Issue C2 Chapter 2 • Updated Disposable Replacement Part list • Updated the nose gear tire size in Tire Inflation Pressures 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 1-6 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 1 1.1.3 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 • 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 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-7 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • 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 • 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 1-8 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 1 • 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 • 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 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-9 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 • 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 1.1.4 Issue C 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) Chapter 4 1-10 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 1 • 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 • 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 REVISIONS / RECORD OF MAINTENANCE MANUAL REVISIONS 1-11 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 Chapter 19 • Changed Complete Aircraft Parachute to ICON Parachute System (IPS) 1-12 REVISIONS / LIST OF EFFECTIVE CHAPTERS ICON A5 / MAINTENANCE MANUAL CHANGE C3 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 C3 28 February 2019 2. GENERAL C3 28 February 2019 3. INSPECTIONS C2 28 February 2019 4. STRUCTURES C2 28 February 2019 5. DOORS AND WINDOWS C0 20 April 2018 6. ELECTRICAL SYSTEM C2 28 February 2019 7. ENVIRONMENTAL CONTROL (UTILITY SYSTEMS) C1 28 February 2019 8. EQUIPMENT AND FURNISHINGS C1 28 February 2019 9. FLIGHT CONTROLS C3 28 February 2019 10. FUEL SYSTEM C2 28 February 2019 11. FUSELAGE AND VERTICAL TAIL C1 28 September 2018 12. HORIZONTAL TAIL C1 28 February 2019 13. INSTRUMENTS (AND AVIONICS) C2 28 February 2019 14. LANDING GEAR C2 28 February 2019 15. PLACARDS AND MARKINGS C1 28 February 2019 16. PROPULSION C2 28 February 2019 17. WING C2 28 February 2019 18. WING FOLD MECHANISM C0 20 April 2018 19. ICON PARACHUTE SYSTEM (IPS) C1 28 September 2018 REVISIONS / LIST OF EFFECTIVE CHAPTERS 1-13 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 1 Applicable to Maintenance Manual Revision: Issue C3 RELATED I NFORMATION : "Manual Revisions" on page 1-14 20. STRUCTURAL REPAIR C0 20 April 2018 21. PAINTING AND COATINGS C0 20 April 2018 22. FEEDBACK FORMS C0 20 April 2018 Chapter Change Date 1-14 REVISIONS / MANUAL REVISIONS ICON A5 / MAINTENANCE MANUAL CHANGE C3 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. 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 1-12 Chapter 2 GENERAL / 2-1 CHANGE C3 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 C3 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 GENERAL / INTRODUCTION 2-3 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.1 Introduction This maintenance manual provides the standard maintenance and inspection procedures for the ICON 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. 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, Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft. 2-4 GENERAL / SYMBOLS ICON A5 / MAINTENANCE MANUAL CHANGE C3 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 C3 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 C3 CHAPTER 2 2.4 Maintenance Terminology and Abbreviations Condition Inspection A detailed inspection accomplished once in the preceding 12 calendar months on a LSA in accor- dance 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 C3 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. A&P Airframe and Powerplant 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 INOP Inoperable EMS Engine Management System LH Left Hand LSA Light Sport Aircraft LSA-RM Light Sport Aircraft—Repairman Maintenance 2-8 GENERAL / MAINTENANCE TERMINOLOGY AND ABBREVIATIONS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 MLG Main Landing Gear MM Maintenance Manual MRA Major Repair and/or Alteration NLG Nose Landing Gear PIM Parachute Installation Manual RF Radio Frequency RH Right Hand TED Trailing Edge Down TEL 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 C3 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. 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. Consumables A list of any consumables items needed to perform the task. If there are none, then it will say ‘None’. Verification Method 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. 2-10 GENERAL / ORGANIZATION AND STRUCTURE OF THIS MANUAL ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 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 C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.6 Maintenance System for Light Sport Aircraft 2.6.1 Introduction Maintenance, inspection, repair, and alteration tasks described in this manual are considered line main- tenance, and the authorizations to perform each individual task can be found in each individual task. There are no heavy maintenance tasks defined in this MM for the A5. 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 There are no heavy maintenance, repairs, or alterations defined in this maintenance manual at this time. These tasks require specialized training, equipment, or facilities. 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. Overhaul tasks are not defined in this maintenance manual. RELATED I NFORMATION : "Organization and Structure of This Manual" on page 2-9 "Condition and 100-Hour Inspection—Paperwork" on page 3-26 "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 C3 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 limitations 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). GENERAL / MAINTENANCE SYSTEM FOR LIGHT SPORT AIRCRAFT 2-13 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 Table 2-1: Summary table of level of certification hierarchy. In any instance, task-specific training is in addition to level of certification. 2.6.6 Major Repairs and Alterations By definition, major maintenance, repairs, and alterations are not addressed in this MM. Any task not defined within this 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. MRAs will require logbook entries and may also require updates to the Pilot’s Operating Handbook. Task Says Owner/Pilot Can Do The Task LSA-RM Can Do The Task A&P Can Do The Task Owner/Pilot X X X LSA-RM X X A&P X 2-14 GENERAL / SAFETY DIRECTIVES AND CONTINUED OPERATIONAL SAFETY ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 2.7 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. The notice of corrective action can be done by three methods: by means of a safety directive, service bulletin, or a notification. A safety directive/alert requires immediate action from the owner/operator. Safety directives/alerts are similar to Airworthiness Directives, however they are not approved by the FAA. They are required by the owner/operator to stay within compliance of the ASTM design specification. Service Bulletins recommend future action and a notification provides important information. Notifications do not neces- sarily recommend future action but are primarily for the release of continued airworthiness information. When corrective actions to the aircraft are required the following information will be included, either directly or by reference, within the notice. • A list of the tools needed to accomplish the task • A list of parts needed to perform the task • The type of maintenance • The level of certification required to perform the task • Detailed instructions and diagrams needed to perform the task • Method to test/inspect to verify ICON will attempt to contact affected owners using the contact information on file. This information can be obtained by contacting ICON Customer Service and support via the following channels: ICON Aircraft, Inc. Attention: Customer Service and Support 2141 ICON Way Vacaville, California 95688 01 855-FLY-ICON (359-4266) Email: support@iconaircraft.com Please be sure to keep your contact information up-to-date. The Appendices contain a Change of Address/Ownership form for this purpose. RELATED I NFORMATION : "Instructions for Reporting Safety of Flight Concerns" on page 2-14 "Feedback Forms" on page 22-2 2.7.1 Instructions for Reporting Safety of Flight Concerns Aircraft owners are responsible for reporting Continued Operational Safety concerns to ICON Aircraft. To notify ICON Aircraft of operational or other safety concerns, fill out a copy of the ‘Continued Oper- ational Safety Reporting Form’ found at the back of this manual and mail or email to ICON Aircraft. You can also contact ICON using the phone numbers or email address shown at the bottom of the form. GENERAL / SAFETY DIRECTIVES AND CONTINUED OPERATIONAL SAFETY 2-15 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 RELATED I NFORMATION : "Safety Directives and Continued Operational Safety" on page 2-14 2-16 GENERAL / MAINTENANCE SCHEDULES ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 2.8 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. RELATED I NFORMATION : "Introduction" on page 3-3 "Interval Maintenance—Operational Hours" on page 3-4 "Interval Maintenance—Calendar Intervals" on page 3-5 "Overhaul Maintenance" on page 3-8 GENERAL / LOGBOOK INSTRUCTIONS 2-17 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 2.9 Logbook Instructions Per 14 CFR Part 43, a maintenance record entry must include the following information. 1) A description of the work performed. 2) The date of completion of the work performed. 3) The name and certificate number (if applicable) of the person performing the work and returning the aircraft to service. 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 model A5 aircraft under the provisions of this exemption must include a reference to this exemption in the maintenance record entry required to be made under the provi- sions of 14 CFR § 43.9 or 43.11, as applicable.” See logbook entry example below. Table 2-2: Example logbook entry referencing FAA Exemption 10829. Name, Certificate Number and Type Date Inspection and Description Signature Brian Anderson, LSA-RM Cert #123456 2015-05-12 IPS removed, serviced, and reinstalled per BRS PIM (ref. FAA Exemption 10829) 2-18 GENERAL / SOURCES TO PURCHASE PARTS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 2.10 Sources to Purchase Parts Parts can be acquired from ICON Aircraft. ICON Aircraft, Inc. 2141 ICON Way Vacaville, CA 95688 +001 707-564-4000 RELATED I NFORMATION : https://www.iconaircraft.com ownersupport@iconaircraft.com "Disposable Replacement Parts" on page 2-19 GENERAL / DISPOSABLE REPLACEMENT PARTS 2-19 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 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. RELATED I NFORMATION : "Sources to Purchase Parts" on page 2-18 Item Part Number Source Main Gear Tires DTAB3D3 Desser Tires Nose Gear Tire ICA013789 Desser Brake Pads ZEA01 Beringer Coarse Fuel Filter FX 375-M Andair Fine Fuel Filter 874060 Rotax/Kodiak Air Filter RU-0800 K&N Filters Spark Plugs Per Rotax Maintenance Manual Rotax/Kodiak Oil Filter 825-012 Rotax/Kodiak Main ELT Battery E E-04.0 ACK Technologies Inc. ELT Remote Control Panel Indicator Battery Eveready PX28L 6 volt Lithium battery Various ELT Audio Annunciator Duracell CR-2,3 Various 2-20 GENERAL / SPECIAL TOOLS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 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. FIGURE 2-1 TIE-DOWN ADAPTER—QRP9C0405 Tool ICON Part Number Tie-Down Adapter QRP9C0405 Fuel Sumping Tool ICA009753 Wing Jack Point Adapter ICA009750 Nose Landing Gear Rigging Tool ITL-1714 Eyeball Vent Tool ITL-1563 Engine Hoist End Effector ITL-902 Gas Spring Compression Tool ITL-971 Rudder Deflection Template ICA013055 Trim Actuator ICA006821 GENERAL / SPECIAL TOOLS 2-21 CHANGE C3 ICON A5 / MAINTENANCE MANUAL CHAPTER 2 FIGURE 2-2 FUEL SUMPING TOOL—ICA009753. FIGURE 2-3 WING JACK POINT ADAPTER—ICA009750. The following list of special tools may be needed to complete the inspection and maintenance of the A5. • Borescope • Tensionmeter • Water Rudder Travel Protractor 2-22 GENERAL / SPECIAL TOOLS ICON A5 / MAINTENANCE MANUAL CHANGE C3 CHAPTER 2 • Rudder Travel Protractor • Digital Protractor • Densimeter • Glycol Tester • Caliper • Mircometer • Calibrated Torque Wrench • Digital Level with 0.1° resolution • 3M ® Adhesion Promoter 111 • 14.125±.125 VDC Charge with current capability of at least 4.8 amperes • DIA .250 Rig Pin • DIA .1875 Rig Pin • Plastic Syringe • Flexible PVC Tubing • ITW Tacky Tape • Inclinometer