SERVICE BULLETIN - SB-011118 REV A

6. Bond in CN609CR3P nut plates in four places on the bottom side of the left and right keel flange in accordance with Clickbond specification CPBS-206E. Installation of the throttle conduit 1. Carefully layout the throttle conduit cable ICA012305 and remove the cable out of the conduit, use care to not allow the cable to get contaminated with dirt or dust or inadvertently wipe the lubricant off the cable. 2. Measure and cut the conduit to 112-114” measured from the end of cable where it enters the metal sheath as shown in Figure 4. Cut the conduit at 114” initially then cut it shorter if necessary. 3. Once conduit is cut to size, strip .7” of conduit plastic coating down to the metal on the opposite end of the conduit as shown in Figure 4 for the conduit terminal. FWD LEFT CN611CR3P ICA012311 AFT RHT Up FWD 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 6 of 15 Figure 4: Cable Conduit measurements 4. Sub assemble the bracket to the conduit by attaching the conduit to the throttle bracket using two AN742F3 P-clamps and two 10F50MTT3 screws with NAS1149C0316R washers as shown in Figure 5 below. Ensure that crimped sleeve on the conduit is between the p-clamps Torque fasters to 26 in-lb. Note: if the P-clamps do not fit perpendicular to throttle conduit because the crimped sleeve is slightly long it is permissible to open up the holes on the bracket slightly to allow the anchor nut to float further. Figure 5: Throttle Bracket Subassembly Conduit Length 112-114” from end of metal sheath Strip .7” of coating down to metal for terminal 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 7 of 15 5. Starting in the center console, route the conduit aft under the center console bracket through the to the aft intercostal ty-rap block and secure the conduit with a TY24MX ty-rap as shown in the Figure 6. Note: Early serial numbered aircraft don’t have a removeable center console bracket as shown below. If the aircraft has a removeable bracket, ensure there is a plastic edging grommet installed between the conduit and bracket to avoid a chafing condition. Figure 6: View Looking aft inside the center console 6. When routing the conduit under the fuel tank ensure the conduit doesn’t become wrapped or entangled with any flight control cables. Adjust as necessary to ensure the conduit passes cleanly between the center section intercostal and the forward bulkhead. 7. Secure the conduit to the newly placed ty-rap block using a TY24MX ty-rap. 8. Route the remaining conduit through the forward main fuselage bulkhead underneath the main landing gear actuator and up the right side of the aft main bulkhead up through the forward side of the right-side firewall access hole as shown the Figure 7 below. Note: Some aircraft don’t have p-clamps as shown but instead installed are ty-wrap blocks. Either configuration is acceptable if the conduit is secure in all the locations shown with either a p-clamp or TY24MX ty- rap. Throttle Conduit Center console bracket: ensure plastic edging grommet is installed if bracket is removable Aft Intercoastal ty-rap block Fuel Tank Bilge Pump 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 8 of 15 Figure 7: Securing locations on the aft fuselage bulkhead (either configuration is acceptable) Either Configuration is Acceptable 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 9 of 15 9. On the firewall side, ensure the conduit is biased to the most forward side of the firewall access hole. Then route the conduit as shown in the photo below. Add F4TAPE to the engine mount and secure throttle cable using a TY24MX ty rap as shown in Figure 8. Figure 8: Firewall side routing of the throttle cable conduit. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 10 of 15 10. Terminate the conduit on the engine side using MA830 plexus adhesive for the epoxy and Loctite 243 on threads of the set screws as shown in Figure 9 below: Figure 9: Installation Instruction for 6271 Slip fit terminal Assembly 11. Final install the throttle bracket into the keel by installing four 10F50MTT3 torque fasteners to 26 in-lb. Installation of throttle cable 1. Carefully insert the previously set a side throttle cable through the ELT access panel and into the conduit. Do not allow the cable to touch surfaces where is could gather dirt or dust. Use care not to permanently deform the cable during the installation process. The cable should easily route through the conduit. If the cable stops and can’t be easily pushed/routed through without excessive twisting or shoving, then the conduit needs to be replaced. 2. Secure the conduit terminal at the engine throttle body as shown in Figure 8 above. 3. Install clevis rod end onto throttle cable. a. Run AN315C3R nut onto threaded end of throttle cable in keel. b. Run ICA012310 rod end onto threaded end of throttle cable. c. Position throttle quadrant lever all the way FWD against the full throttle handle stop. d. Align clevis end of rod end with hole in throttle quadrant lever. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 11 of 15 e. Measure the distance shown (between the end of the throttle cable guide tube end and beginning of threads on throttle cable). Adjust rod end as required to achieve the required measurement of .375”. NOTE: Ensure the rubber grommet/seal on the end of the guide tube is installed and seated fully on the guide tube or the .375” measurement will be incorrect. Figure 10 f. Fit check the clevis rod end to throttle quadrant lever with MS20392-2R11 pin, g. Verify measurement is still .375±.125 with handle at full throttle position. h. Remove the rod end from the throttle lever to tighten jam nut against rod end and torque to 20-25 in-lb. Apply torque stripe. i. Final attachment of the rod end to throttle quadrant lever using the MS20392-2R11 pin, NAS1149C0316R washer, and MS24665-151 cotter pin. Bend cotter pin around clevis pin according to standard practice. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 12 of 15 4. Attach throttle cable to engine as follows and shown in Figure 11 and 12 below: a. Move throttle handle to FULL OPEN THROTTLE position (against FWD stop). b. Back off handle .100” from FWD stop Figure 11: Throttle Cable Rigging c. On engine side, at throttle lever, thread cable through the hole in the cable fixation screw. d. Pull cable tight to remove any slack. e. Attach screw to throttle lever as shown in Figure 12 with included bushing, washer, and nut. f. With cable pulled tight, tighten cable fixation fastener. g. Ensure bushing bears against washer on opposite side of throttle lever (not clamping throttle lever), allowing the cable fixation fastener to rotate freely. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 13 of 15 Figure 12: Throttle attachment at engine throttle body. h. (This step requires 2 technicians – one at handle, one at engine). In cockpit, retract throttle handle to contact aft stop (idle position). At engine, ensure lever idle stop contacts idle adjustment screw at the same time or just before the throttle handle contacts the aft stop. Adjust the position of cable in cable fixation fastener as required. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 14 of 15 i. (This step requires 2 technicians – one at handle, one at engine). In cockpit, move throttle handle to full throttle position (FWD stop). At engine, ensure the lever full throttle stop contacts the throttle body before the throttle handle contacts the FWD stop. Adjust position of cable in cable fixation fastener as required. j. When cable adjustment is complete, torque cable fixation fastener to 35±5 in-lb. Apply torque stripe. Do not over tighten and ensure the cable fixation fastener can still rotate on the throttle lever of the throttle body once torqued. CAUTION: DO NOT DAMAGE THE BUSHING BY OVER TORQUEING CABLE FIXATION SCEW 5. Trim the excess end of the throttle cable to .75-1.00” from throttle body fixation fastener. 6. Move the throttle to full and idle several times watching how the cable enters the conduit near the throttle lever especially at full throttle. Any tendency for the throttle cable to buckle or kink is un-acceptable and must be troubleshot. This may mean replacement of the conduit. The throttle should be able to move through the normal range of motion with no kinking tendencies. If the kinking tendency should occur after new conduit installation, contact ICON customer service and support for assistance. 7. Re-install the ELT in accordance with the latest maintenance manual. Reassembly: 1. Reinstall the center console armrest and bucket, throttle handle, throttle bezel, both seat backs and baggage floors in accordance with the most current ICON A5 maintenance manual (ICA000833) 2. Perform engine run and verify normal throttle operation from full throttle to idle throttle. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A ICA009719-B PAGE 15 of 15 WARRANTY: ICON Certified Service Providers: Please submit an invoice for warranty reimbursement of 16 labor hours upon completion. Please reference service bulletin number SB-011118. Make the following logbook entry: “Service Bulletin SB-011118 has been complied with and reported to ICON Aircraft Customer Support. This service bulletin supersedes SD-062117”. If you need assistance relocating your A5 to your home base or temporary storage arrangements, please contact ICON Aircraft and ask for Customer Service and Support. If you are no longer owner/operator of this aircraft, please forward this information to the present owner/operator and notify ICON Aircraft, Owners Center at: ICON Aircraft 2141 ICON Way Vacaville, CA 95688 (855) FLY-ICON or (707) 564-4000 support@iconaircraft.com Please include the aircraft registration number, serial number, your name, and if known the contact information of the new owner/operator. 2141 ICON Way, Vacaville, CA 95688 ‐ Tel: 707.564.4000 – www.iconaircraft.com SERVICE BULLETIN SB-011118 REV A SAFETY DIRECTIVE APPROVAL Flight Sciences Manager 1/11/2018 NAME TITLE DATE NAME TITLE DATE NAME TITLE DATE