Aerodyne ICON User manual

Manual
TM162
Edition 02 - 2004
ICON harness container sizes
I2 Reserve size 99-110
I3 110-135
I4 135-150
I5 150-175
I6 175-190
S7 190-220
S8 220-250
ICON HARNESS CONTAINER
PACKING MANUAL
AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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ICON PACKING MANUAL Edition of 02-2004
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AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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The Aerodyne Creed:
"Our Customer"
The world is getting smaller and at Aerodyne, we have a global "Vision" of the future. We know
our customers are "Smart" and we need innovative new products, of the highest quality, and
tested to the highest standards. We need programs that appeal to you and add value,
responsiveness and convenience.
We have made the commitment never to be content and never follow the "others". We will lead
the way and expand the envelope. We will be the "Icon", the symbol of a new standard in our
sport.
We know we haven't chosen the easiest path, but few things worth having are easy. You are the
primary focus, your needs and your convenience. It is this concept we shall build upon,
because ultimately you, our customer, will determine our success.
Aerodyne International (USA, France, South Africa, the World)

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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WARNING!
PROPER TRAINING AND / OR EXPERIENCE ARE REQUIRED TO LOWER THE RISK OF
SERIOUS INJURY OR DEATH.
READ THIS WARNING LABEL AND APPROPRIATE OWNERS MANUAL AND PACKING
INSTRUCTIONS AND COMPLETED A “CONTROLLED PROGRAM OF INSTRUCTION” IN
THE USE OF THIS PARACHUTE ASSEMBLY.
READ THIS WARNING LABEL AND APPROPRIATE OWNERS MANUAL AND PACKING
INSTRUCTIONS AND COMPLETED AT LEAST 100 RAM-AIR PARACHUTE JUMPS.
LOWER THE RISK OF DEATH, SERIOUS INJURY, CANOPY DAMAGE AND HARD OPENINGS
BY NEVER EXCEEDING THE MAXIMUM LIMITS : 136 Kg 150 Knots
PARACHUTE SYSTEMS SOMETIMES FAIL TO FUNCTION PROPERLY EVEN WHEN CORRECTLY ASSEMBLED,
PACKED AND OPERATED SO THAT YOU RISK SERIOUS INJURY OR DEATH EACH TIME YOU USE THIS OR
ANY PARACHUTE SYSTEM!
1
2
A
OR
B
NEVER USE THIS EQUIPMENT UNLESS YOU HAVE:
AERODYNE SYSTEMS

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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OPERATING INSTRUCTIONS
2.1 RESERVE ASSEMBLY
2.1.1 - Connection rapide links
2.1.2 - Soft links
2.1.3 - Connect canopy to Container
2.1.4 - PACKING INSTRUCTIONS
2.2 MAIN ASSEMBLY
2.2.1 - Connector links
2.2.2 - Soft links
2.2.3 - Connect canopy to container
2.2.4 - PACKING INSTRUCTIONS
MAINTENANCE
3.1 MAINTENANCE PROCEDURES
3.2 FREQUENCY
3.3 STORAGE
1
2
3
TECHNICAL SPECIFICATIONS
1.1 INTRODUCTION
1.2 DESCRIPTION
1.3 MARKING & COMPONENTS LIST
1.4 TECHNICAL SPECIFICATIONS
AND LIMITATIONS
SUMMARY

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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1.1 INTRODUCTION
THE ICON HARNESS CONTAINER MUST BE CHECKED AND ASSEMBLED BY A QUALIFIED
RIGGER.
Before assembly, check the harness, container and all components, ensuring that the Reserve
and Main container sizes are compatible with the Reserve and Main canopies, and deployment
systems with which it is to be used.
1.2 DESCRIPTION: Icon is an individual harness container.
Main risers with three ring system
Chest strap
Reserve Handle
Main lift web
Cut away handle
Leg Straps Leg adjusters
Leg pad
Hand deploy
Main container
Reserve container

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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1.3 Marking & list of components
1.3.1 Label on front left reserve riser
1.3.2 List of components:
AERODYNE SYSTEMS P.O.BOX 1616 VERULAM 4340 SOUTH AFRICA
Max.operating limits: 136 kg 150 kt
Average peak force during 4.3.4 strength tests: 5.45 G’s
Part No: Serial number: Date of MFG:
Container size: Harness Size:
CERTIFICATION: TSO C23d

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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1.4 TECHNICAL SPECIFICATIONS AND LIMITATIONS
QUALIFIED RESERVE DEPLOYMENT SYSTEM: FREEBAG WITH SPRING PILOT CHUTE
PACKING: AS SPECIFIED IN THIS MANUAL.
MAIN DEPLOYMENT SYSTEM:
DEPLOYMENT BAG WITH HAND DEPLOY PILOT CHUTE.
STATIC LINE.
SPECIFICATIONS: THE ICON HARNESS CONTAINER IS CERTIFIED UNDER TSO C23d.
It is produced in different sizes in accordance to the TSO C23d SMART range of canopies.
RESERVE CANOPY USE: Must be used with TSO certified reserve canopies.
LIMITATIONS:
ICON container sizes:
ICON Harness size: The Icon harness is produced in the following sizes:
MAXIMUM SPEED: 150 KT
MAXIMUM WEIGHT IS DEFINED BY THE LOWER OF THE TWO : 136 KG OR THE RESERVE
CANOPY TSO MAXIMUM WEIGHT
I2
I3
I4
I5
I6
S7
S8
99-110 275 cu.in. max
110-120 293 cu.in. max
120-150 346 cu.in. max
150-175 384 cu.in. max
175-220 476 cu.in. max
190-250 488 cu.in. max
220-250 488 cu.in. max
90 - 104 327 cu.in. max
110-135 368 cu.in. max
130-150 393 cu.in. max
150-175 416 cu.in. max
175-210 465 cu.in. max
230-250 507 cu.in. max
250-270 527 cu.in. max
A=
B =
C =
D =
E =
F =
G =
H =
XXSpecial
XSmall
Small
Medium
Large
XLarge
XXLarge
XXXL Special
SMART Reserve Max accepted Main canopy accepted
SIZE

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Cut away handle with rigid Puff
Reserve handle with rigid Puff Reserve toggle
Reserve handle position
Cut away handle position
Metallic reserve handle
Major Components & Accessories:

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Main pin toggle
Miniforceä Type 17 risers - Pin Toggle
Stainless steel leg strap adjusters with buffer Route the webbing as shown on picture
Adjustment
Elastic keepers are MANDATORY on
leg straps
Type 8 buffer
No slippage on 0,900 tons

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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2 OPERATING INSTRUCTIONS
2.1 ASSEMBLY
INSPECTION BEFORE PACKING
1. Read and understand this manual and be qualified by proper instruction for sport parachuting
activities.
2. Check both 3-Ring releases to see that they are correctly assembled, and the release handle is
securely velcroed to the main lift web.
3. Check the main container closure for the correct pin position and the correct routing of the bridle.
4. Check the reserve container for correct pin closure and routing of the ripcord. Be sure the reserve
ripcord handle is well seated in its velcro pocket.
5. The main pilot chute must be protected by its pouch, but the handle must be easily visible
and accessible
6. Ensure that the reserve and main canopy size is compatible with the harness-container and
deployment system with which it is to be used.
7. Prior to assembly and/or packing a thorough inspection of the Icon harness and container must
be completed.
- Reserve container
- Main container
- Harness
- All cable housings
- All stitching
- All grommets
- Reserve handle integrity and correct size fitted.
- Cut away housing integrity and correct size fitted.
- Reserve risers and deployment brake system
Take note of any worn, damaged, corroded or incorrectly rigged components, which must be
repaired or replaced before the harness container is packed for use.
For Reserve canopy installation ,read and follow the instructions included in theReserve canopy
instruction manual.
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AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
Read the warning on page 3 of this manual and follow the instructions before packing and/or using the product.
Soft links connection
Soft link for reserve canopies.
PN: P 1487-01
Soft link for Main canopies on miniforce risers.
PN: P 1487-00
Reserve canopy assembly:
If soft links are used follow the instructions below:
Installation procedure on front and rear reserve risers:
Secure the Soft Link ring in the webbing pocket, and hand tack as shown.
Knot type below
1256
4
3
TM
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AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Reserve toggle assembly:
Pass the lower steering line through the rear riser ring.
Pass the line through the toggle grommet and loop around the toggle. Pull tight..
Set the toggle into the lower steering line brake loop. And slide the toggle finger into the pocket.
Stow the extra line and close the velcro. Fix and secure the toggle on the rear riser.
Reserve canopy assembly:
If you use connector links:
After canopy installation, don’t forget to tighten the connector links (Do not overtighten!).
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AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Connect front lines to the front risers
Pass the lines through the slider grommets.
For Connection see page 11.
Connect rear lines..
Pass the line through the slider grommets.
For Connection see page 11
Connect the steering lines.
Pass the steering line through the rear slider
grommet and through the guide ring on the rear
reserve riser.
For assembly of steering toggle see page 12.
Front risers
Soft link or
Connector link
Slider Grommets

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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CYPRES Assembly:
MANDATORY: Only use a Cypres closure loop with the Icon Harness and Container
Adjust the length and tighten the knot.
To set the reserve closure loop and washer use the following method as shown.
TOTAL LENGTH
ICON 2 ICON 3 ICON 4 ICON 5 ICON 6 ICON S7 ICON S8
SMART 99 X
SMART 110 X X
SMART 120 X X
SMART 135 X
SMART 150 X X
SMART 160 X
SMART 175 X X
SMART 190 X X
SMART 220 X X X
SMART 250 X X
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AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Reserve container CYPRES installation
Sandard unit control installation: Into spandex pocket on the back pad.

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Clear window CYPRESS control unit installation:
Place the two tyraps with the head on the right side as shown in the drawings, place the CYPRESS
control unit as shown in the picture, tighten tyraps and cut the extra lenght off. Follow the drawings.

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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2.2 PACKING INSTRUCTIONS
2.2.1 RESERVE CONTAINER
For packing of the Reserve container, follow the Reserve canopy manufacturer’s WARNING,
instructions and recommendations.
For the closing of the Reserve Container follow the Icon Manuals WARNINGS, Instructions
and recommendations.
Packing of the Reserve Canopy and Container must be completed by a qualified rigger.
Set the toggle into the lower steering line brake loop. Slide the toggle finger into the pocket.
Stow the extra line and close the velcro. Fix and secure the toggle on the rear riser.

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Prepare the reserve deployment bag shape as shown
Lay the risers flat against the container wall.
Push and compress the lower corners of the deployment bag
into the reserve container (see arrows).
Fold the reserve bridle as shown (3 folds on each side).
Place the deployment bag and pass the closure loop
through the deployment bag central grommets.
Place the Spring ejector plate and fold the remaining
bridle on top of plastic flap.
3 folds
3 folds
AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Pass a pull up cord cleanly through the pilot chute
from bottom to top plate.
Ensure the lower spring coil is up against the spring ejector plate.
Top plate grommet
Lock the pilot chute in position with a temporary pin Close the right flap
Close upper flap
Close the left flap

AERODYNE SYSTEMS - PO BOX 1616 VERULAM 4340 SOUTH AFRICA
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Install the reserve handle and close the lower flap with the pin.
If you install a RSL: Route the cable through the guide rings as shown.
RSL Lanyard
Verify the reserve handle pull force is between 5 lbs (22,2 Newtons) minimum and 22 lbs (97,9 Newtons maximum)