Liberty XL2 Maintenance Manual

Hide thumbs Also See for XL2:

page of 497

/ 497
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Maintenance Manual

1383 General Aviation Drive

Melbourne, FL 32935

800-759-5953

Table of Contents

Chapters

Table of Contents

Need help?

Do you have a question about the XL2 and is the answer not in the manual?

Questions and answers

Summary of Contents for Liberty XL2

Page 1 Maintenance Manual 1383 General Aviation Drive Melbourne, FL 32935 800-759-5953...
Page 2: Table Of Contents
Table of Contents XL2 Airplane Table of Contents Record of Revision Check List List of Temporary Revisions List of Service Bulletins Table of Chapters General Chapters Introduction General Description Airworthiness Limitations Time Limits/Maintenance Checks/Inspection Intervals Dimensions and Areas Lifting and Jacking...
Page 3 Table of Contents XL2 Airplane Airframe Chapters Structures Doors Fuselage Stabilizers Windows Wings Propeller Chapter Propeller Power Plant Chapters Standard Practices-Engine Power Plant Engine Engine Fuel System Ignition Engine Air Engine Controls Engine Indicating Exhaust Starting Wiring Diagrams...
Page 4: Record Of Revision
Record of Revisions Revision Date Affected Pages Number Original Issue April 2005 April 2005 4-2, 4-4 Replace: 5- Inspection Check list pg., May 2005 5,6,7. 31-Table of Contents. Add: 31-10...
Page 5: Check List
Check List This Check List should be used for control of all revisions issued and installed in this manual. The affected pages of any revision, as well as the Record of Revisions must be inserted into the manual upon receipt. The pages superseded by the revision must be removed and destroyed.
Page 6: List Of Temporary Revisions
List of Temporary Revisions Revision Date Inserted Inserted Revision Date Inserted Inserted Number: Issued: Number: Issued:...
Page 7: List Of Service Bulletins
List of Service Bulletins Service Revision Inserted Service Revision Inserted Bulletin: Number: Bulletin: Number:...
Page 8: Introduction
Introduction XL2 Airplane Chapter 01 INTRODUCTION P/N 135A-970-006 - 1 - INITIAL RELEASE...
Page 9 Introduction XL2 Airplane Introduction Table of Contents GENERAL REVISIONS WARNINGS, CAUTIONS, NOTES MANUAL ARRANGEMENT MAIN CHAPTER GROUPS P/N 135A-970-006 - 2 - INITIAL RELEASE...
Page 10 XL2 Airplane General: This Maintenance Manual is intended to furnish maintenance personnel with all data required for normal maintenance of the Liberty XL2 airplane. It comprises detailed system and subsystem descriptions, troubleshooting tables, component removal, reinstallation procedures, and detailed maintenance procedures.
Page 11 Introduction XL2 Airplane Changed Text: Changes to text as a result of revisions are indicated by a vertical line in the margin adjacent to the text that has been changed. Blank Pages: Blank pages may appear in either originally issued or revised sections of the Maintenance Manual.
Page 12 Introduction XL2 Airplane The chapters are combined in main groups as follows: GENERAL Chapters 01 - 12 EQUIPMENT Chapters 20 - 34 AIRFRAME Chapters 51 - 57 PROPELLER Chapter 61 ENGINE Chapters 71 - 92 Each of the main groups as well as each chapter is divided by a cover page showing chapter number and the title.
Page 13: General Description
General Description XL2 Airplane CHAPTER 03 GENERAL DESCRIPTION P/N 135A-970-006 Chap 03 INITIAL RELEASE - 1 -...
Page 14 General Description XL2 Airplane Chapter 03 Table of Contents Chapter 03 Table of Contents Chapter 03-00 General Description Vendor Documentation P/N 135A-970-006 Chap 03 INITIAL RELEASE - 2 -...
Page 15 Melbourne, Florida, USA, 32935 1-800-759-5953 and is approved in the normal airworthiness category. The XL2 may be operated under DAY or NIGHT VFR conditions depending on installed standard and optional equipment. IFR certification is pending. Description: The Liberty XL2 airplane is a low-wing two-place aircraft with tricycle landing gear.
Page 16 The rudder is operated by pushrods attached to adjustable cockpit rudder pedal assemblies. Aluminum trailing edge flaps are electrically operated. The XL2 is powered by an air-cooled Teledyne Continental Motors IOF-240-B four cylinder, horizontally opposed, fuel injected engine. The engine is rated at 125 continuous SAE horsepower at 2800 RPM.
Page 17 General Description XL2 Airplane Aircraft measurements: P/N 135A-970-006 Chap 03-00 INITIAL RELEASE - 5 -...
Page 18 General Description XL2 Airplane P/N 135A-970-006 Chap 03-00 INITIAL RELEASE - 6 -...
Page 19 General Description XL2 Airplane Aircraft access panels. P/N 135A-970-006 Chap 03-00 INITIAL RELEASE - 7 -...
Page 20 General Description XL2 Airplane P/N 135A-970-006 Chap 03-00 INITIAL RELEASE - 8 -...
Page 21: Airworthiness Limitations
Airworthiness Limitations XL2 Airplane CHAPTER 04 AIRWORTHINESS LIMITATIONS 04-TITLE P/N 135A-970-006 Page 4 - 1 April 2005...
Page 22 Airworthiness Limitations XL2 Airplane AIRWORTHINESS LIMITATIONS The Airworthiness Limitations Section is FAA approved and specifies inspections and other maintenance required under paragraphs 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved. DATE APPROVED /s/ Ronald F.
Page 23 Airworthiness Limitations XL2 Airplane SECTION 04-10: AIRFRAME The structural inspection procedures and inspection intervals for both life limited components and components subject to a more detailed level of inspection are listed below in Section 4-20. 04-00-00 P/N 135A-970-006 Page 4 - 3...
Page 24 Airworthiness Limitations XL2 Airplane SECTION 04-20: COMPONENTS SUBJECT TO LIFE LIMITS OR REQUIRING MORE DETAILED LEVELS OF INSPECTION Items listed below are considered components that are either life-limited with distinct times between replacement, or components subject to a higher level of inspection.
Page 25 The inspection procedure for the XL2 throttle cable installation will be conducted as directed in Chapter 5 of these Instructions for Continued Airworthiness. The inspection procedure for the XL2 fuselage will be conducted as directed in Chapter 5 of these Instructions for Continued Airworthiness.
Page 26 Airworthiness Limitations XL2 Airplane SECTION 04-30 PAINT FINISH To ensure that the temperature of the load-bearing composite structure is kept below the structural temperature limit, the outer surface of the composite components must be painted white except for areas of registration marks, placards, and minor trim.
Page 27: Time Limits/Maintenance Checks/Inspection Intervals
Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane CHAPTER 05 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS P/N 135A-970-006 Chap 05 INITIAL RELEASE - 1 -...
Page 28 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Chapter 05 Table of Contents Chapter 05 Table of Contents Chapter 05-00 General Chapter 05-10 Time Limits Chapter 05-20 General 50, 100, and 500 hour inspections, checklist Check Flight checklist Chapter 05-30 General Inspections...
Page 29: General
Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Time Limits/Maintenance Checks/Inspection Intervals Section 05-00 General: Maintenance personnel should refer to chapters 04 and 05 as guidelines for proper scheduling and execution of inspections and maintenance. The inspections and intervals described in these two chapters are considered the minimum required to maintain the airplane in airworthy condition.
Page 30: Time Limits
Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Section 05-10 Time Limits: Component time limits: Component Specified Time Between Overhaul Engine, Teledyne Continental Motors, model IOF-240-B. Including accessories 2000 operating hours or 12 years Propeller, Sensenich model W69EK7-63G To be inserted P/N 135A-970-006...
Page 31: General
NOTE: The procedures required for an annual inspection are the same as those required for a 100 hour inspection. They are required for any Liberty XL2 airplane that is flown less than 100 hours in a 12 calendar month period.
Page 32 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane INSPECTION CHECKLIST FOR LIBERTY XL-2 AIRCRAFT S/N:_________________ Registration:__________________ Date:___________ Engine operating hrs:_________ Type of inspection:_____ Airplane hours:__________ Inspection items 50-hr 100-hr 500-hr Initials Prior to inspection: 1. Review Airworthiness Directive compliance. 2. Review Service Bulletins (SB).
Page 33 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Inspection items 50-hr 100-hr 500-hr Initials 2. TCM IOF-240-B Maintenance Manual, p/n: M-22, Thoroughly wash engine with approved cleaning solution listed in Chapter 3 of TCM manual, and visually inspect. 3. Perform all engine inspections, and maintenance in accordance with TCM IOF-240-B Maintenance Manual, p/n: M-22, and other manuals as maybe applicable.
Page 34 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Inspection items 50-hr 100-hr 500-hr Initials WARNING: WORN SPARK PLUGS THAT ARE ALLOWED TO CONTINUE IN SERVICE MAY CAUSE EXCESSIVE LOADING OR PREMATURE BREAKDOWN OF THE FADEC HIGH VOLTAGE COILS. 12. Check all engine controls, control cables, control rod...
Page 35 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Inspection items 50-hr 100-hr 500-hr Initials Propeller: 1. Ref. Chap 61-10, Remove spinner; check spinner and spinner bulkheads for cracks, dents, run-out, loose or missing fasteners. 2. Ref. Chap 61-10, Check propeller mounting bolt torque (must be performed every 50 hours in addition to 50, and 100 hour checks).
Page 36 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Inspection items 50-hr 100-hr 500-hr Initials 14. Ref. Chap 11-00, Confirm all required instrument and control knob and handle markings and placards. 15. Ref. Chap 33, Check all interior and exterior lights for proper operation.
Page 37 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Inspection items 50-hr 100-hr 500-hr Initials 16. Ref. Chap 28, Check fuel lines for leakage. 17. Ref. Chap 27-30, Inspect hinges and Anti-Servo tabs for condition. Verify proper deflection and direction of anti- servo tabs using electric trim system.
Page 38 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Inspection items 50-hr 100-hr 500-hr Initials 11. Tires: check for condition, wear, proper inflation (50 psi). 12. Main and nose wheel rims: check for cracks. 13. Ref. Chap 32-40, Wheel bearings: check for play, corrosion, smooth running.
Page 39: Check Flight Checklist
Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane CHECK FLIGHT Liberty Aerospace Page 1 of 2 DATE:……………. Registration Number:……………….. Pilot:……………… Airport:______________________ Take-Off time:……………… Weather Conditions:………………… Landing time:……….……… ………………………………………………….. Findings Functional Check and Flight Behavior, Note: Use the POH for preflight checklist. Pass...
Page 40 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane CHECK FLIGHT Liberty Aerospace Page 2 of 2 DATE:……………. Findings Functional Check and Flight Behavior, Note: Use the POH for preflight checklist. Pass Fail Taxiing and Take-off behavior Airspeed Indicator Vertical speed indicator Compass...
Page 41: General Inspections
Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Section 05-30 General Inspections: General: Preflight and Postflight inspections are part of standard operating procedures. They are generally performed by the pilot on a daily or more frequent basis. Preflight Inspections: This inspection should be performed before each and every flight by the pilot that will be making the flight.
Page 42: Unscheduled Inspections
Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane Section 05-40 Unscheduled Inspections: General: Unscheduled inspections are only performed in the event that during flight or ground operations an incident occurs which is not part of normal flight or ground operation, and which could cause a defect or interfere with the airworthiness of the airplane.
Page 43 Time Limits/Maintenance Checks/Inspection Intervals XL2 Airplane D) Non operation of more than 30 days: If the airplane has not been operated for 30 days or more, refer to Chapter 10-30 for details for long term storage and return to service.
Page 44: Dimensions And Areas
Dimensions and Areas XL2 Airplane CHAPTER 06 DIMENSIONS AND AREAS P/N 135A-970-006 Chap 06 INITIAL RELEASE - 1 -...
Page 45 Dimensions and Areas XL2 Airplane Chapter 06 Table of Contents Chapter 06 Table of Contents Chapter 06-00 General Three Views Dimensions Areas Adjustment Values for Mass Balance, Ref. Doc:135A-926- 008E Rigging Procedure, Ref. Doc: 135A-911-050B APPENDIX Adjustment Values for Mass...
Page 46 Dimensions and Areas XL2 Airplane Chapter 06 Dimensions and Areas Chapter 06-00 GENERAL: Dimensions given in this Chapter are in decimal inches (i.e. inches and tenths of inches). Weights are in pounds (decimal if necessary for precision). Moments are in foot-pounds or inch-pounds (decimal if necessary for precision). Angles are given in degrees (decimal if necessary for precision).
Page 47 Dimensions and Areas XL2 Airplane THREE VIEWS P/N 135A-970-006 Chap 06-00 INITIAL RELEASE...
Page 48 Dimensions and Areas XL2 Airplane DIMENSIONS: Overall Dimensions: Wingspan (without anti-collision lights): 28 ft. Wingspan (including anti-collision lights): 28.61 ft. Length: 243.8 in. Height: 68.0 in. to top of fuselage. Wings: Airfoil: Liberty Custom Airfoil. Wing area: 112 ft. Mean Aerodynamic Chord (MAC): 4.00 ‘...
Page 49 1.1 Scope: Mass balancing of control surfaces is used to prevent the onset of flutter or divergence at high airspeeds. The Liberty XL-2 has rudder, aileron and horizontal stabilizer surfaces that use counter balance weights to balance the surface about the surface hinge line.
Page 50 Dimensions and Areas XL2 Airplane 135A-20-132 STBD AILERON + MASS BALANCE 135A-30-103 TAILPLANE AND HARDWARE-PORT 135A-30-104 TAILPLANE AND HARDWARE-STBD 135A-30-131 RUDDER ASSY 2 PURPOSE 2.1 Description of Components: The rudder, ailerons and horizontal stabilizer surfaces will be mass balanced prior to flight.
Page 51 Dimensions and Areas XL2 Airplane 5. Observe and record the surface behavior without the balance weights present. 6. The weight of the mass balance is engineered to be heavy on the balance arm. When the aileron is held in the vertical clamp jig it falls into a state of ‘over balance’.
Page 52 Dimensions and Areas XL2 Airplane 11. Once both surfaces have been reattached to the wing, verify that the aileron operation is in its correct sense and that the surfaces are free from binding or galling that could potentially interfere with the safe operation of the aircraft.
Page 53 Dimensions and Areas XL2 Airplane P/N 135A-970-006 Chap 06-00 INITIAL RELEASE...
Page 54 Dimensions and Areas XL2 Airplane 2.2.2 Horizontal Stabilizer Balancing: To balance the horizontal stabilizer, the following procedure should be followed. The Horizontal stabilizer is defined here as the Horizontal stabilizer surfaces, tab surfaces, tab drive mechanism in the surface, and all parts associated with the complete assembly of the horizontal stabilizer and tab structures.
Page 55 Dimensions and Areas XL2 Airplane 5. Observe and record the surface behavior without the balance weights present. 6. Note that the weight of the mass balance is engineered to be heavy on the balance arm such that it is probable that the horizontal stabilizer surface + balance weight falls into a state of ‘over balance’.
Page 56 Dimensions and Areas XL2 Airplane 12. Reset the horizontal stabilizer to its equilibrium position. 13. Place the scale now under the forward tip of the mass balance arm such that when the equilibrium state is disturbed by lowering the mass balance arm by few degrees, the scale stops the horizontal tail rotation at 5°.
Page 57 Dimensions and Areas XL2 Airplane 2. Hold the hinge in a level horizontal position with vertical clamp jig. 3. Lubricate the hinge so that it is free to operate. 4. Operate the rudder in the vertical clamp jig to verify that the hinge is level and that it operates about the collinear axis without binding or galling through its full range of movement.
Page 58 Dimensions and Areas XL2 Airplane 7. Should the upward load required to keep rudder level require less than 1.5 lb, remove the rudder horn from the rudder assembly by de-riveting. Gain access to the mass balance inside the rudder horn and remove AN960 washers, as needed for required weight, from mass balance mounting screws.
Page 59 The purpose of this document is to instruct the aircraft maintenance technician on the proper rigging procedures of the Liberty XL-2 aircraft, to a condition where all control surfaces move full and freely in the correct sense. Once set, rigging...
Page 60 Dihedral- The lateral angle of the wings about the longitudinal axis that the wings are set at from horizontal, providing natural lateral stability. For the Liberty XL2 the inclined angle from wing root centerline to wing tip centerline is 4.25°. (Note: This corresponds to 3.97°...
Page 61 XL2 Airplane Incidence- The angle that the wing root is set to the fuselage when viewed from the side. For the Liberty XL2 the inclined angle at the root is 2.5° leading edge up relative to the fuselage horizontal datum.
Page 62 Verify the safety wire does not pass through the witness hole in the rod end fitting. Lock push rod jam nuts (4 places) and re-check set up, readjust and lock as required. Record the action in Liberty Maintenance Manual. 2.1.7 Remove Blocks: Remove blocks from aileron profiled stops and retain with aileron check block neutral port and starboard for re-check.
Page 63 Verify that prior to moving any control surfaces that all control surfaces are free to move without any obstruction, internal or external and all surfaces are mass balanced per the Liberty mass balance specification. 2.2.3 Battery Power: Ensure that battery power is available and that applying power will not interfere with any concurrent procedures or harm any open electrical systems.
Page 64 Dimensions and Areas XL2 Airplane 2.2.5.3 Control Column movement in All Possible Directions: Move the control column in all possible directions. Check complete aileron and horizontal stabilizer for clearance at all possible interfaces between the operator and the observer. All clearance below 0.3” are to be...
Page 65 Dimensions and Areas XL2 Airplane After adding/removing shims, repeat 2.2.7.1 and verify lateral travel is in tolerance band .020/.040. Verify fixing screws associated with additional shims are safe; i.e., 1.5 thread protruding (fit next size up per standard practice, if necessary).
Page 66 Dimensions and Areas XL2 Airplane 2.2.7.7 Power OFF: Place the master power switch to OFF. 2.2.8 Trim Tab-Horizontal Stabilizer: Note: This is a powered control system, ensure surfaces and engine propeller plane are all clear prior to selecting aircraft battery “on”.
Page 67 Trim tab movement should not cause movement of the horizontal stabilizer circuit or surface. Such movement should be recorded and reported to Liberty engineering office for evaluation. 2.2.8.8 Needle Indicator Set up Trim Tab: With trim tab neutral (Horizontal Stabilizer neutral also), the needle should be indicating against the mid travel position.
Page 68 Dimensions and Areas XL2 Airplane 2.2.8.9 Power OFF: Place the master power switch to OFF. Rigging Procedure Verification: 2.3.1 Rigging Datum and Leveling Means: Position horizontal aircraft on jacks and set in rigging position port door sill ±0.1 and across port and starboard door sills to be °.
Page 69 Incidence is measured at the wing root and the wing tip using the “SMART LEVEL”™. Refer to drawing 135A-06-001 for proper placement of the “SMART LEVEL”™ and the acceptable limits. Record the port reading in Liberty maintenance manual and repeat for the starboard wing. P/N 135A-970-006 Chap 06-00...
Page 70 Dimensions and Areas XL2 Airplane INCIDENCE MEASUREMENT 2.3.3.3 Washout: Washout is the difference between the root and tip incidence. Record differences in incidence at each matched location port to starboard in Liberty maintenance manual. For location and acceptable limits refer aircraft geometry 135A-06-001, sheet 3, zone A2.
Page 71 Dimensions and Areas XL2 Airplane Note: Visually check wing push rods for approximately equal amount of thread extension, four places port and four places starboard. Note: The geometry of the aileron circuit is such that range of aileron movement and differential is set by the attitude of the aileron quick connect at the wing root.
Page 72 Dimensions and Areas XL2 Airplane 2.3.4.7 Calculate Total Aileron Range Angles: For total range port add maximum positive angle to maximum negative angle, obtained for the port aileron in step 2.3.4.6 above and record. Repeat for starboard aileron using the starboard aileron angle values obtained in step 2.3.4.6 above.
Page 73 Dimensions and Areas XL2 Airplane If the straight edge is in full contact with the upper surface of the wing and the surface of the flap then no flap adjustment is necessary port. Continue to step 2.3.5.6. Note: Make an additional “flap up” positional check extending a rigging line from inboard trailing edge of the flap to the outboard trailing edge of wing tip.
Page 74 Dimensions and Areas XL2 Airplane 2.3.5.6 Flap Chord Angle: Record the attitude angle of the port flap upper surface at the root while the flap is fully retracted. Place the flap in the fully deployed position. With flap fully deployed, record attitude angle of flap at the same position on flap surface.
Page 75 Dimensions and Areas XL2 Airplane 2.3.6.5 Calculate Total Horizontal Stabilizer Angles: For the total range of the horizontal stabilizer add the maximum positive angle to maximum negative angle and record. For the total nose down angle of the horizontal stabilizer, subtract the neutral negative angle from maximum negative angle and record.
Page 76 Dimensions and Areas XL2 Airplane 2.3.7.3 Trim Tab Adjustment If trim tabs are neutral, i.e., aligned with tail plane trailing edge then proceed to the next step. Where adjustment is required to achieve neutral, proceed as follows: Back off the jam nut and rotate barrel of trim actuator (extending/retracting) until trim tab matches port trailing edge of horizontal stabilizer.
Page 77 Dimensions and Areas XL2 Airplane 2.3.8.3 Rudder Adjustment: If the rudder is in neutral i.e., trailing edge aligned with 0° on rudder angle gauge, proceed to next step. If the rudder is misplaced on either side of neutral then adjust by extending or contracting one of the three (3) rudder push rods within the system: rudder to bellcrank pushrod;...
Page 78 Dimensions and Areas XL2 Airplane For acceptable limits asymmetry, refer Aircraft Geometry 135A-06-001. 2.3.10.1 Aileron Adjustment: To increase range of movement port to within acceptable limits decrease the overall length of port aileron push rod situated between aileron torque tube on aircraft centerline and port aileron quick connect. Release jam nuts and rotate barrel one half turn only to decrease push rod assembly.
Page 79 Dimensions and Areas XL2 Airplane 2.3.11.3 Main Wheel Track Determination: The absolute value of the difference between Dim A and Dim B should be less than or equal to .1”. If the difference is greater than .1” refer to drawing 135A-10-071 “SPACE FRAME U/C”...
Page 80 LEFT HAND DOWN STABILIZER (MOVABLE) RIGHT HAND DOWN LEFT HAND DOWN TRIM (ANTI SERVO) TAB RIGHT HAND DOWN RUDDER LEFT RIGHT RUDDER TRIM TAB LEFT RIGHT FIGURE 3 LIBERTY XL-2 FLIGHT CONTROL OPERATIONAL FORM P/N 135A-970-006 Chap 06-00 INITIAL RELEASE -35-...
Page 81 Dimensions and Areas XL2 Airplane APPENDIX CONTENTS: Adjustment Values for Mass Balance, 135A-926-008E Rigging Procedure, 135A-911- 050B FAR 23, Sec 23.629 Flutter 135A-00-025 Aircraft Assy Basic 135A-02-509/510 Aileron Check Block Neutral Fuselage 135A-02-511 Aileron Yoke Block 135A-02-513 Rudder Angle Gauge...
Page 82: Lifting And Jacking
Lifting and Jacking XL2 Airplane CHAPTER 07 LIFTING and JACKING P/N 135A-970-006 Chap 07 INITIAL RELEASE - 1 -...
Page 83 Lifting and Jacking XL2 Airplane Chapter 07 Table of Contents Chapter 07 Table of Contents Chapter 07-00 Lifting and Jacking General Required Equipment Chapter 07-10 Lifting the Airplane General Lifting the Airplane Lowering the Airplane Chapter 07-20 Jacking the Airplane...
Page 84: Leveling And Weighing
Lifting and Jacking XL2 Airplane Lifting and Jacking Chapter 07- 00 General: The airplane can be raised from the ground by lifting from above or by jacking from below. The preferred method is to jack the airplane. Lifting or jacking may be necessary for purposes of leveling and weighing the airplane (see Chapter 08) or servicing or replacing the landing gear or components (see Chapter 32).
Page 85 Lifting and Jacking XL2 Airplane Chapter 07- 10 Lifting: General: CAUTION: WHEN LIFTING BY THE FUSELAGE, AS DESCRIBED BELOW, THE AIRPLANE IS NOT SUPPORTED LATERALLY, AND CAN SWAY. THEREFORE, ALL LIFTING SHOULD BE PERFORMED INDOORS ONLY, AND PERSONNEL SHOULD BE AVAILABLE TO STEADY THE AIRPLANE AT ITS WINGS AND TAIL DURING THE ENTIRE TIME IT IS LIFTED.
Page 86 Lifting and Jacking XL2 Airplane c. Secure a nylon webbing strap snugly around the aft fuselage approximately halfway between wing trailing edge and leading edge of horizontal tail surfaces. Use padding material as necessary to protect fuselage. P/N 135A-970-006 Chap 07-10...
Page 87 Lifting and Jacking XL2 Airplane Route a nylon webbing strap through the top of the strap around the aft fuselage described in step “c” above. a. Secure the straps from the engine mount and the top of the aft fuselage to the hook of the crane or hoist to be used.
Page 88 Lifting and Jacking XL2 Airplane Chapter 07- 20: Jacking: General: For purposes of changing or servicing a single main landing gear wheel, the airplane may be jacked up on one side only, using a single jack at the applicable main gear jack point.
Page 89 Lifting and Jacking XL2 Airplane b. Place a suitable jack under the nose gear jack point. c. Operate all three jacks simultaneously to raise airplane from the ground. ALTERNATE METHOD: a. Place a suitable jack under each main gear jack point.
Page 90 Lifting and Jacking XL2 Airplane CHAPTER 08 LEVELING AND WEIGHING P/N 135A-970-006 Chap 08 INITIAL RELEASE - 1 -...
Page 91 Lifting and Jacking XL2 Airplane Chapter 08 Table of Contents Chapter 08 Table of Contents Chapter 08 -00 Leveling and Weighing General Leveling Weighing Required Equipment Procedure Weight and Balance Measurement/ Calculation Form P/N 135A-970-006 Chap 08 INITIAL RELEASE - 2-...
Page 92 Chapter 08- 00 General: Operation of the Liberty XL-2 airplane within its established weight and balance limits is essential to both flying qualities and performance. The airplane must be weighed, and its center of gravity determined by calculation, any time equipment or components are added or removed.
Page 93 Lifting and Jacking XL2 Airplane a. Verify that all required equipment is installed and complete. Ensure that any other items are removed from baggage area and cockpit storage pockets, etc. b. Drain all fuel from airplane, then add published amount of unusable fuel to fuel tank (1.5 U.S.
Page 94 Lifting and Jacking XL2 Airplane P/N 135A-970-006 Chap 08-00 INITIAL RELEASE...
Page 95 Lifting and Jacking XL2 Airplane AIRPLANE WEIGHING RECORD Scale - Tare wt = Net wt Position Reading (lbs) (lbs) L Main - L R Main - R Nose - N Total as weighed EMPTY CENTER of GRAVITY CALCULATION Individual Wt...
Page 96: Towing And Taxiing
Towing and Taxiing XL2 Airplane CHAPTER 09 TOWING AND TAXIING P/N 135A-970-006 Chap 09 INITIAL RELEASE - 1 -...
Page 97 Towing and Taxiing XL2 Airplane Chapter 09 Table of Contents Chapter 09 Table of Contents Chapter 09 -00 Towing and Taxiing General Equipment and Accessories Chapter 09-10 Towing Towing / Positioning by Hand Towing / Positioning by Vehicle Chapter 09-20...
Page 98 • A tow bar suitable for hand towing and positioning of the airplane is provided as standard equipment and is usually carried in the airplane. • A vehicle tow bar is available from Liberty Aerospace. Use of locally- fabricated vehicle tow bars is discouraged.
Page 99 Towing and Taxiing XL2 Airplane Chapter 09-10 TOWING: TOWING / POSITIONING BY HAND: a. Attach the tow bar to the nose landing gear, (see note in 09-00). b. Remove chocks. c. Release parking brake. d. Move airplane to desired position.
Page 100 Towing and Taxiing XL2 Airplane e. Chock main wheels. f. Remove tow bar from airplane and tow vehicle. g. Set parking brake, (if necessary and depending on operator policy). P/N 135A-970-006 Chap 09-10 INITIAL RELEASE...
Page 101 TAXIING: GENERAL: The Liberty XL-2 is controlled on the ground by individual left and right finger operated wheel brakes. The paired left and right wheel brake levers are located on the cockpit center console. Very tight turn radii can be achieved by operation of an individual brake.
Page 102 Enter cockpit; secure seat belt; release parking brake; check brake operation by pulling aft on both brake levers. d. Set parking brake. e. Start engine (see Liberty XL-2 Approved Flight Manual / Pilot Operating Handbook). f. Taxi airplane to desired position using minimum required power. Operate left or right brake to steer airplane left or right.
Page 103 Mooring and Parking XL2 Airplane CHAPTER 10 MOORING AND PARKING P/N 135A-970-006 Chap 10 INITIAL RELEASE - 1 -...
Page 104 Mooring and Parking XL2 Airplane Chapter 10 Table of Contents Chapter 10 Table of Contents Chapter 10 -00 Mooring and Parking General Equipment Required Chapter 10-10 Parking Short Term Parking Long Term Parking Chapter 10-20 General Mooring (Tie Down) P/N 135A-970-006...
Page 105 Mooring and Parking Chapter 10- 00 General: Due to its small size and light weight, the Liberty XL-2 should always be moored (tied down) when not in use. Pilots and maintenance personnel should familiarize themselves with the procedures described below to help prevent damage from wind or turbulence caused by other aircraft.
Page 106 Mooring and Parking XL2 Airplane Chapter 10-10 PARKING 1. Short-term Parking: a. Taxi or tow airplane to desired parking position. b. Align nose of airplane into the wind. c. Ensure nose wheel is centered. d. In windy or gusty weather, moor (tie down) airplane (see Chapter 10-20).
Page 107: Servicing
Mooring and Parking XL2 Airplane d. Refer to engine, electrical, and fuel system chapters of this manual for information on required servicing for long-term storage. P/N 135A-970-006 Chap 10-10 INITIAL RELEASE...
Page 108 Mooring and Parking XL2 Airplane Chapter 10-20 MOORING (TIE-DOWN): GENERAL: The airplane has three mooring points: one under each wing, and one under the tail. Mooring rings are provided to secure tie down ropes into the mooring points. Park the airplane (see Chapter 10-10).
Page 109 Placards and Markings XL2 Airplane CHAPTER 11 PLACARDS AND MARKINGS P/N 135A-970-006 Chap 11 INITIAL RELEASE - 1 -...
Page 110 Placards and Markings XL2 Airplane Chapter 11 Table of Contents Chapter 11 Table of Contents Chapter 11-00 General Material Removal and Installation Chapter 11-10 Location of Placards Interior Exterior Notes P/N 135A-970-006 Chap 11 INITIAL RELEASE - 2-...
Page 111 Placards and Markings XL2 Airplane Chapter 11 Placards and Markings Chapter 11-00 General: Placards are used for identification and indication purposes. They describe the function, operation, and operating limitations of the various systems and equipment. This chapter describes the location of the placards on the interior and the exterior surfaces of the airplane.
Page 112 Placards and Markings XL2 Airplane Chapter 11-10 Location of Placards: In addition to the fire proof identification plate, the following placards are installed. Interior: Reference drawing number 135A-08-003. P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 113 Placards and Markings XL2 Airplane P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 114 Placards and Markings XL2 Airplane P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 115 Placards and Markings XL2 Airplane Exterior: Reference drawing number 135A-08-001. P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 116 Placards and Markings XL2 Airplane P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 117 Placards and Markings XL2 Airplane P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 118 Placards and Markings XL2 Airplane P/N 135A-970-006 Chap 11-10 INITIAL RELEASE...
Page 119 Placards and Markings XL2 Airplane Notes: Install registration number decals and placards on painted prepared surface per LIB PS 135A-926-994. Smooth away any air pockets using vinyl applicator prior to sealing vinyl edges with edge sealer. Apply oil capacity and engine oil placards to interior surface of oil servicing hatch cover.
Page 120 Servicing XL2 Airplane CHAPTER 12 SERVICING P/N 135A-970-006 Chap 12 INITIAL RELEASE - 1 -...
Page 121 Servicing XL2 Airplane Chapter 12 Table of Contents Chapter 12 Table of Contents Chapter 12 -00 Servicing General Chapter 12-10 Replenishing Fuel System Oil System Brake System Tires Battery Chapter 12-20 Lubrication General Lubrication Schedule Chapter 12-30 Unscheduled Service Exterior Cleaning...
Page 122 Servicing Chapter 12- 00 General: This chapter describes normal servicing procedures for the Liberty XL-2 airplane. These procedures include replenishment of consumables and periodic lubrication of certain components. Procedures for servicing other components at certain intervals are also included in this chapter.
Page 123 REPLENISHING: Fuel System Refueling: The Liberty XL-2’s fuel supply is contained in a single tank of 28 US gallons capacity. The tank is manufactured from welded aluminum material and is located in the center fuselage. The tank cover forms the seatback structure for the left and right seats.
Page 124 Servicing XL2 Airplane Only fuel types approved in the Approved Flight Manual / Pilot’s Operating Handbook (AFM/POH) may be used. These are Aviation Gasoline (AVGAS), Grade 100LL (colored blue) and Aviation Gasoline (AVGAS), Grade 100 (colored green). Defueling: The airplane can be defueled via the fuel sump drain valve on the bottom of the fuselage.
Page 125 Servicing XL2 Airplane Thereafter, only mineral oil, MIL-C-6529, TYPE ll, or Ashless Dispersant oils specifically approved by Teledyne Continental Motors for the IOF-240-B-4 engine should be used. It is recommended that the brand, type, and grade of oil currently used is recorded and the information be kept on board the airplane for reference by pilots and maintenance personnel.
Page 126 Engine oil can be drained via a drain plug at the bottom of the engine oil sump. For detailed engine oil draining procedures, see Chapter 72. Only the following manufacturers and grades of Approved Ashless Dispersant Oils may be used in the Liberty XL-2 airplane: Manufacturer Oil Grade and Type...
Page 127 Servicing XL2 Airplane Sinclair Oil Company Sinclair Avoil Texaco, Inc. Texaco Aircraft Engine Oil Premium AD Total France Total Aero DM 15W50 Union Oil Co. of California Union Aircraft Engine Oil HD Approved mineral oil MIL-C-6529 TYPE II Brake System: Routine servicing of the brake system is limited to checking and refilling the brake fluid reservoir with Mil-H-5606A hydraulic fluid.
Page 128: Tires
Batteries: The Liberty XL-2 has two recombinant-gas type (RG) batteries. Both are installed in the aft fuselage and may be accessed by removing the rear baggage compartment closeout bulkhead.
Page 129: Lubrication General
Servicing XL2 Airplane Chapter 12-20 SCHEDULED SERVICING: LUBRICATION: GENERAL: This chapter details specific areas and components that require periodic lubrication. In addition, it identifies areas which must not be lubricated. LUBRICATION SCHEDULE: Lubrication Schedule Time Aircraft Part : Interval: Lubricant...
Page 130: Exterior Cleaning
Servicing XL2 Airplane Chapter 12-30 UNSCHEDULED SERVICING: Exterior Cleaning: Wash the exterior of the airplane with generous amounts of water and, if desired, a mild soap. Small amounts of common cleaner/degreaser products may be applied by hand (rag, sponge) to remove resistant oil or exhaust stains.
Page 131: Engine Cleaning
Servicing XL2 Airplane Engine Cleaning: The engine may be cleaned with standard cold solvents (Stoddard solvent, etc.) using a low pressure spray only. CAUTION: Ensure that all engine and accessory breathers and vent openings are sealed (tape, plastic bags, etc.) before cleaning engine. Do not spray solvent directly on or near any electric or electronic (FADEC) accessories or connectors when cleaning engine.
Page 132 Standard Practices Airframe XL2 Airplane CHAPTER 20 STANDARD PRACTICES AIRFRAME P/N 135A-970-006 Chap 20 INITIAL RELEASE - 1 -...
Page 133 Standard Practices Airframe XL2 Airplane Chapter 20 Table of Contents Chapter 20 Table of Contents Chapter 20 -00 Standard Practices Airframe General Bolt Types Standard Torques Special Torques Torque Measuring Details Safety Wiring Cotter Pins Tab Washers P/N 135A-970-006 Chap 20...
Page 134 BOLT TYPES: Bolts used in the Liberty XL-2 conform to the AN specification. In general, they are protected against corrosion by cadmium plating. Corrosion-resistant steel bolts are marked with a dash on the bolt head.
Page 135 Standard Practices Airframe XL2 Airplane WARNING: THE CADMIUM PLATING ON CORROSION-RESISTANT AIRCRAFT FASTENERS HAS TOXIC PROPERTIES AND, IF ABSORBED IN THE BODY, MAY LEAD TO SYMPTOMS OF HEAVY METAL POISONING. NEVER PLACE ANY CADMIUM-PLATED FASTENER OR COMPONENT IN YOUR MOUTH.
Page 136 Standard Practices Airframe XL2 Airplane Installation Torque for Bolt/Nut Combinations in Composite Structures: Nut installation torque values: Nominal Fastener Mid-Range Range (in-lbs) Diameter (inch) Values(in-lbs) Min-Max 0.1640 17.5 15-20 0.1900 32.5 25-40 0.2500 90-100 0.3125 202.5 180-225 0.3750 300-390 Locknut torque values:...
Page 137 Standard Practices Airframe XL2 Airplane TORQUE MEASURING DETAILS: Self-locking nuts: If self-locking nuts are used, the torque required to overcome the locking feature (friction torque) must be determined by measuring indicated torque while the nut is being tightened but before it has seated against the washer or other seating surface, and added to the torque values given in the tables above.
Page 138 Standard Practices Airframe XL2 Airplane Lock wire shall be new at each application. Various examples of lockwiring patterns are shown in fig. 2, “General Lock Wire Patterns.” All items to be safety wired must be properly torqued. Applying torque above or below specified limits to obtain alignment of holes is not permitted.
Page 139 Standard Practices Airframe XL2 Airplane Insert half of the required length of wire through the first unit and bend around the head of the unit. Direction of wraps and twist of strands shall be such that the loop around the unit comes under the strand protruding from the hole so that the loop will stay down and will not tend to slip up and leave slack loop.
Page 140 Standard Practices Airframe XL2 Airplane An alternate method may be used: a. Insert cotter key as far as possible through castellated nut with “eye” of cotter key horizontal. b. Trim both legs of key to appropriate length to allow ends to be bent back and pushed into slots in castellated nut adjacent to slot occupied by body of cotter key.
Page 141 Standard Practices Airframe XL2 Airplane CAUTION: DISCARD TAB WASHER IMMEDIATELY UPON REMOVAL. NEVER RE-USE A TAB WASHER. P/N 135A-970-006 Chap 20-00 INITIAL RELEASE...
Page 142: Environmental Systems
Environmental Systems XL2 Airplane CHAPTER 21 ENVIRONMENTAL SYSTEMS P/N 135A-970-006 Chap 21 INITIAL RELEASE - 1 -...
Page 143 Environmental Systems XL2 Airplane Chapter 21 Table of Contents Chapter 21 Table of Contents Chapter 21-00 General Chapter 21-40 Heating – (Reserved) Chapter 21-50 Cooling Chapter 21-60 Temperature Control Environmental System Troubleshooting Table P/N 135A-970-006 Chap 21 INITIAL RELEASE - 2-...
Page 144 Environmental Systems XL2 Airplane Chapter 21-00 GENERAL: The airplane is equipped with a passive air ventilation (fresh air) system. Air is ducted in to the airplane through NACA cut-outs in the forward fuselage (see Cooling 21-50). Pilot side air vent Co-pilot/Passenger air vent A fresh air window vent is also installed in the cabin doors.
Page 145 Environmental Systems XL2 Airplane Chapter 21-40 HEATING: Reserved: P/N 135A-970-006 Chap 21-40 INITIAL RELEASE - 1-...
Page 146 Environmental Systems XL2 Airplane Chapter 21-50 COOLING: An NACA-type flush inlet on each side of the forward fuselage is connected, through molded, bonded duct to directional outlets at the left and right lower corners of the instrument panel. The outlet can be directed for pilot or passenger comfort.
Page 147 Environmental Systems XL2 Airplane Chapter 21-60 TEMPERATURE CONTROL: Cool air is regulated by means of opening or closing the vent located on each lower corner of the instrument panel. P/N 135A-970-006 Chap 21-60 INITIAL RELEASE - 1-...
Page 148 Environmental Systems XL2 Airplane ENVIRONMENTAL SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy fresh from inlet blocked investigate, repair instrument panel outlet(s) outlet blocked repair P/N 135A-970-006 Chap 21-60 INITIAL RELEASE...
Page 149: Communications
Communications XL2 Airplane CHAPTER 23 COMMUNICATIONS P/N 135A-970-006 Chap 23 INITIAL RELEASE - 1 -...
Page 150 Communications XL2 Airplane Chapter 23 Table of Contents Chapter 23 Table of Contents Chapter 23-00 General Chapter 23-10 Speech Communication GNS 530 GPS/NAV/COM GNS 430 GPS/NAV/COM Chapter 23-51 Audio/ICS Systems Troubleshooting Table P/N 135A-970-006 Chap 23 INITIAL RELEASE - 2-...
Page 151 Communications XL2 Airplane Chapter 23 COMMUNICATIONS Chapter 23-00 GENERAL: The airplane is equipped with a Garmin VHF radio system, used for communication between the airplane and a ground station or between airplanes. It operates in the frequency ranges of 118.000 to 136.975 MHz, and has 760 channels with a separation of 25 kHz.
Page 152 Communications XL2 Airplane Chapter 23-10 SPEECH COMMUNICATION – Garmin GNS 530 GPS/NAV/COM, GNS 430 GPS/NAV/COM: Two VHF transceivers are installed on the airplane, and are controlled by the audio panel. A separate VHF communications antenna, located atop the aft fuselage, is provided for each transceiver. The forward antenna is for the #1 system, the aft antenna is for the #2 system.
Page 153 Communications XL2 Airplane REMOVAL AND REPLACMENT OF COMMUNICATIONS TRANSCEIVER: NOTE: Any maintenance operations beyond simple removal or replacement of a communications transceiver must be accomplished by an appropriately equipped and certificated avionics maintenance facility. REMOVAL: a. Ensure that both aircraft battery switch and avionics master switch are OFF.
Page 154 Communications XL2 Airplane Chapter 23-51: AUDIO/ICS SYSTEMS: An integrated audio selector panel / intercom system is installed. The transmitter selector switch routes audio from the pilot and copilot microphones to the #1 or #2 communications transmitters. The receiver selector switches allow audio from the #1 or #2 communications receivers, the VHF navigation receiver(s), and the marker beacon receiver to be routed to the crew headsets.
Page 155 Communications XL2 Airplane REPLACEMENT: a. Ensure that both aircraft battery switch and avionics master switch are OFF. b. Check mating connectors on rear of unit and in mounting tray to ensure no pins are bent. c. Verify that retaining claw is in released position. If necessary, insert hex key into hole in faceplate and turn CCW.
Page 156 Communications XL2 Airplane COMMUNICATIONS SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Unable to transmit or Defective power supply repair receive; communications wiring transceiver display dark Defective COMM circuit replace breaker If other avionics are also repair/replace without power: defective avionics master switch or...
Page 157: Electrical Power
Electrical Power XL2 Airplane CHAPTER 24 ELECTRICAL POWER P/N 135A-970-006 Chap 24 INITIAL RELEASE - 1 -...
Page 158 Electrical Power XL2 Airplane Chapter 24 Table of Contents Chapter 24 Table of Contents Chapter 24-00 Electrical Power General Troubleshooting Chapter 24-10 Alternator Drive Belt Removal Belt Replacement Chapter 24-30 DC Generation Alternator Alternator Removal Alternator Replacement Alternator Control Unit...
Page 159 Electrical Power XL2 Airplane Chapter 24-40 External Power, (Reserved) Chapter 24-60 DC Electrical Load Distribution Subsection 24-61 DC Power Distribution Subsection 24-62 Avionics Power Distribution Avionics Troubleshooting P/N 135A-970-006 Chap 24- INITIAL RELEASE - 3-...
Page 160 Electrical Power XL2 Airplane Chapter 24 Electrical Power Chapter 24-00 GENERAL: The airplane is equipped with a 14-volt (nominal) single-wire ground-return electrical system. Primary power is generated by a belt-driven alternator mounted at the front of the engine. Two 12-volt maintenance-free recombinant- gas (RG) type lead-acid batteries are mounted in the aft fuselage.
Page 161 Electrical Power XL2 Airplane Electrical system voltage and alternator output amperage are displayed on the integrated engine instrument system VM1000FX (see Chapter 77). An Alternator Failed (ALT FAIL) warning light on the instrument panel illuminates to warn the pilot when the alternator is not providing sufficient power to the aircraft electrical system.
Page 162 Electrical Power XL2 Airplane Chapter 24-10 ALTERNATOR DRIVE: The alternator is driven by a V-belt using pulleys on the alternator and on the engine crankshaft. Belt tension should be checked as part of the regular preflight inspection: application of a force to the midpoint of the belt, halfway between the pulleys, should cause a deflection of approximately 1/2 in.
Page 163 Electrical Power XL2 Airplane REMOVAL/REPLACEMENT OF ALTERNATOR BELT: WARNING: ALTERNATOR BELT REPLACEMENT REQUIRES REMOVAL AND REPLACEMENT OF THE PROPELLER. IMPROPER TORQUING OF PROPELLER BOLTS MAY CAUSE BOLT OR PROPELLER FAILURE AND RESULT IN INJURY OR DEATH> NOTE: SEE CHAPTER 61 FOR PROPELLER REMOVAL / REPLACEMENT PROCEDURES AND CORRECT PROPELLER BOLT TORQUE VALUES.
Page 164 Electrical Power XL2 Airplane c. Place replacement belt around engine crankshaft and alternator pulleys. d. Secure alternator attachment and belt tension adjustment nuts but do not tighten fully. e. Move (rotate) alternator away from engine to tension belt. NOTE: Alternator belt tension should be such that Alternator fan and pulley can not be rotated without excessive hand force.
Page 165 Electrical Power XL2 Airplane Chapter 24-30 DC GENERATION: ALTERNATOR: The alternator (nominal capacity 60 amps maximum at 14 vdc maximum) is mounted on the right side of the front of the engine. Maintenance operations are normally limited to removal and replacement of the alternator. For further service of the alternator, refer to Teledyne Continental Motors form no.
Page 166 Electrical Power XL2 Airplane e. Disconnect field wire from “F1” terminal on alternator, Aux. wire, and Ground wire. f. Relieve alternator belt tension (see Chapter 24-10, above). g. Remove alternator mounting and belt tension adjustment bolts and remove alternator. REPLACEMENT: a.
Page 167 Electrical Power XL2 Airplane c. Disconnect connector from ACU. d. Remove ACU. REPLACEMENT: a. Reverse above steps. P/N 135A-970-006 Chap 24-30 INITIAL RELEASE - 3-...
Page 168 Electrical Power XL2 Airplane ALTERNATOR SUBSYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy No power supplied by Alternator failed replace alternator with engine running; FAIL ACU failed replace warning light illuminated, voltmeter <13.75v Cabling, connectors, repair electrical connections Failed BAT / ALT master...
Page 169 Electrical Power XL2 Airplane Chapter 24-31 BATTERY: The primary and secondary batteries are located in the aft fuselage and are accessed by removing the baggage compartment closeout panel and the secondary closeout panel. They are of the maintenance-free recombinant-gas lead-acid type. Maintenance is limited to removal and replacement of either or both batteries as required.
Page 170 Electrical Power XL2 Airplane The primary battery is connected to the airplane power distribution bus via a battery contactor (relay) and a 70-amp circuit breaker. Note that battery voltage is applied to the coil of this contactor at all times. The instrument panel battery switch (left side of the combination BAT / ALT master switch) completes the coil circuit to ground.
Page 171 Electrical Power XL2 Airplane BATTERY SUBSYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Battery will not come battery discharged charge battery online defective master switch replace defective battery replace contactor defective diode on X1-X2 replace terminals of contactor defective wiring repair...
Page 172 Electrical Power XL2 Airplane Chapter 24-40 EXTERNAL POWER: Reserved. P/N 135A-970-006 Chap 24-40 INITIAL RELEASE - 1-...
Page 173 Electrical Power XL2 Airplane Chapter 24-60 DC ELECTRICAL LOAD DISTRIBUTION: SUBSECTION 24-61 DC POWER DISTRIBUTION: DC power from both the battery is routed to the main distribution bus through a 70-amp circuit breaker. Power from the alternator is connected directly to the main distribution bus, with control and protection provided by the ACU.
Page 174 Electrical Power XL2 Airplane AVIONICS POWER SUBSYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy No power to avionics defective avionics master replace components switch defective avionics master replace relay Master circuit breaker replace defective wiring repair P/N 135A-970-006 Chap 24-60 INITIAL RELEASE...
Page 175 Equipment/Furnishings XL2 Airplane CHAPTER 25 EQUIPMENT/FURNISHINGS P/N 135A-970-006 Chap 25 INITIAL RELEASE - 1 -...
Page 176 Equipment/Furnishings XL2 Airplane Chapter 25 Table of Contents Chapter 25 Table of Contents Chapter 25-00 Equipment / Furnishings General Chapter 25-10 Flight Compartment Subsection 25-11 Cases / Containers Chapter 25-50 Cargo Compartment Chapter 25-60 Emergency Equipment Subsection 25-61 Fire Extinguisher...
Page 177 Equipment/Furnishings XL2 Airplane Subsection 25-64 Emergency Transmitter Locator (ELT) ELT Operational Check ELT Batteries P/N 135A-970-006 Chap 25- INITIAL RELEASE - 3-...
Page 178 Equipment/Furnishings XL2 Airplane Chapter 25 Equipment/Furnishings Chapter 25-00 GENERAL: The airplane’s accommodation includes the flight compartment, for the pilot and copilot or passenger and a contiguous baggage area immediately to the rear of the flight compartment. P/N 135A-970-006 Chap 25-00...
Page 179 Equipment/Furnishings XL2 Airplane Chapter 25-10 FLIGHT COMPARTMENT: Furnishings in the flight compartment include removable carpets, removable seat and back cushions, and four-point harnesses for both occupants. The carpets and seat cushions are held in place by Velcro. Seat belt and shoulder harness components can be removed by removing the bolts and washers securing them to their attachment points.
Page 180: Flight Controls
Equipment/Furnishings XL2 Airplane Chapter 25-50 CARGO COMPARTMENT: The cargo (baggage) compartment is immediately aft of, and contiguous with, the flight compartment. The carpet on the floor of the cargo compartment is secured with hook-and-loop fasteners. An access plate of composite material in the cargo compartment floor is provided for maintenance of flight control components in the center fuselage area.
Page 181 Equipment/Furnishings XL2 Airplane Chapter 25-60 EMERGENCY EQUIPMENT: SUBSECTION 25-61 FIRE EXTINGUISHER: A portable fire extinguisher is secured behind the co-pilot/passenger seat in the baggage compartment. It must be serviced and maintained in accordance with its manufacturer’s instructions. SUBSECTION 25-62 Safety Hammer:...
Page 182 Equipment/Furnishings XL2 Airplane SUBSECTION 25-64 EMERGENCY LOCATOR TRANSMITTER (ELT): An Emergency Locator Transmitter (ELT) is installed in the rear fuselage. It will function automatically in the event of sudden impact or excessive deceleration forces and will broadcast an internationally recognized distress signal on frequencies of 121.5 MHz and 243.0 MHz for a minimum of 72 hours after...
Page 183 Equipment/Furnishings XL2 Airplane The ELT main batteries must be replaced every 12 months or sooner if the ELT fails an operational check. NOTE: Avoid unnecessary ELT operational checks, as any operation of the ELT reduces its battery life. ELT OPERATIONAL CHECK: (PER FAA ORDER 7310.3s, Chapter 3-3-7)
Page 184 Equipment/Furnishings XL2 Airplane j. Reconnect ELT antenna coaxial cable. k. Replace aft baggage compartment closeout. l. Make required entry in aircraft records. ELT BATTERY REPLACEMENT: a. Remove aft baggage compartment closeout to access ELT. b. Disconnect ELT antenna coaxial cable.
Page 185 Flight Controls XL2 Airplane CHAPTER 27 FLIGHT CONTROLS P/N 135A-970-006 Chap 27 INITIAL RELEASE - 1 -...
Page 186 Flight Controls XL2 Airplane Chapter 27 Table of Contents Chapter 27 Table of Contents Chapter 27-00 General Chapter 27-10 Ailerons Aileron R&R Aileron wing Bellcrank R&R Aileron Pushrod R&R Troubleshooting Chapter 27-20 Rudder Rudder R&R Troubleshooting Chapter 27-30 Elevator and Tabs Stabilator R&R...
Page 187 Flight Controls XL2 Airplane Chapter 27 Flight Controls Chapter 27-00 GENERAL: The flight controls of the airplane include conventional ailerons and rudder and a stabilator with an antiservo tab. All flight controls are operated by pushrods, with dual controls operating the ailerons and stabilators and dual rudder pedals operating the rudder.
Page 188 Flight Controls XL2 Airplane Chapter 27-10 AILERONS: The airplane ailerons are of conventional aluminum construction and are hinged to the lower wing surface by conventional piano hinges. Each aileron incorporates two mass balance weights. The aileron drive system is laid out as follows:...
Page 189 Flight Controls XL2 Airplane In the wing, a single pushrod passes from the quick-connect assembly at the root through an anti-buckling support approximately midway along its length to a bell- crank located forward and just inboard of the aileron root rib. Another pushrod transmits motion from the bell-crank to the inboard end of the aileron.
Page 190 Flight Controls XL2 Airplane WARNING: The ailerons are mass-balanced control surfaces. If mass balance weights are removed, they must be marked for replacement in the proper position. Any repairs made to ailerons, including repainting, require that the balance of the control surface be checked before it is reinstalled.
Page 191 Flight Controls XL2 Airplane d. Remove 2 lower bolts of lower bellcrank mount to wing. e. Remove the lower mount. f. Remove the bolt and nut from the intermediate rod-end. g. Remove the bellcrank and bearing. 2. BELLCRANK REPLACEMENT: a. Reinstall bell-crank and bearing to wing and torque to 240 +/- 20 in/lbs, replace cotter pin.
Page 192 Flight Controls XL2 Airplane 2. PUSHROD REPLACEMENT: a. Insert pushrod into wing (ensure correct orientation of wing and aileron ends). b. Reinstall bolt securing pushrod bearing end to wing bell-crank and torque to 240 +/- 20 in/lbs, replace cotter pin.
Page 193 Flight Controls XL2 Airplane b. Reinstall bolt securing inboard pushrod end bearing to aileron quick- connect device and torque to 240 +/- 20 in/lbs, replace cotter pin. c. Reinstall bolt securing outboard pushrod end bearing to aileron wing bell- crank and torque to 240 +/- 20 in/lbs, replace cotter pin.
Page 194 Flight Controls XL2 Airplane Chapter 27-20 RUDDER: The airplane rudder is of conventional aluminum construction. It is attached to the right side of the fuselage vertical fin by a full-length piano hinge. A fixed ground-adjustable trim tab is fitted to the rudder.
Page 195 Flight Controls XL2 Airplane Left (pilot) and right (copilot) rudder pedal assemblies are connected to a transverse torque tube behind the instrument panel. Left/right movement of the pedals rotates the torque tube. This rotation deflects the rudder via a series of bellcranks, idler bearings, and pushrods passing through the cockpit center console and aft fuselage.
Page 196 Flight Controls XL2 Airplane RUDDER REMOVAL AND REPLACEMENT: 1. RUDDER REMOVAL: a. Deflect rudder fully to the right. b. Remove bolts securing the rudder hinge to the right side of the vertical fin, note that the hinge remains with the rudder.
Page 197 Flight Controls XL2 Airplane RUDDER SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Stiffness or binding in dirty, “dry,” or defective Lubricate with Corrosion rudder system rod end bearings in X or replace as rudder linkage necessary Dirty or dry components Lubricate with Corrosion in the rudder pedal assy.
Page 198 Flight Controls XL2 Airplane Chapter 27-30 ELEVATOR AND TAB: The airplane uses “a stabilizer and anti-servo tab. A fore and aft deflection of the cockpit control stick(s) causes an up/down rotation of the entire horizontal tail surfaces. Anti-servo tabs on the trailing edge of each stabilator deflect in the same direction as surface movement to provide self-centering as well as an appropriate force gradient or “control feel.”...
Page 199 Flight Controls XL2 Airplane P/N 135A-970-006 Chap 27-30 INITIAL RELEASE...
Page 200 Flight Controls XL2 Airplane Access to the control stick pitch bearing and forward pitch pushrod is gained by removal of the fuselage belly fairing. Access to the idler bell-crank and forward end of the aft pushrod is gained by removing the panel in the floor of the baggage compartment.
Page 201 Flight Controls XL2 Airplane TRIM SERVO REMOVAL AND REPLACEMENT: 1. TRIM SERVO REMOVAL: a. Position pitch trim to full nose-down position (requires aircraft electrical system to be powered). b. Ensure BAT / ALT master switch is OFF. c. Remove trim servo access plate (rearmost plate on lower right side of aft fuselage).
Page 202 Flight Controls XL2 Airplane a. Adjust length of bearing end of replacement servo to 0.8 inches, measured from center of bearing hole to flat surface of end of extensible portion of servo, by loosening jam nut and screwing bearing end in or out as required.
Page 203 Flight Controls XL2 Airplane ELEVATOR AND PITCH TRIM SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Binding or stiffness in rod-end bearings replace as necessary pitch trim circuit Looseness in pitch bearings or mounting replace as necessary control bolts scoring on trim drive to...
Page 204 Flight Controls XL2 Airplane Chapter 27-50 FLAPS: The airplanes single-slotted wing flaps are of conventional aluminum construction. Each flap is attached to the wing by three hinges set approximately six inches below the wing lower surface. The flaps are driven by a single electrical actuator operating a cross-tube between the left and right flaps.
Page 205 Flight Controls XL2 Airplane FLAP REMOVAL AND REPLACEMENT: 1. FLAP REMOVAL: a. Fully extend flaps. b. Support flap at each end. Remove (3) cotter pins from hinge bolts. Remove (3) hinge bolts and spacers. c. Flap can now be rotated around point at which flap spigot engages flap drive cross tube bearing.
Page 206 Flight Controls XL2 Airplane d. Remove bolt securing bearing end of actuator to flap cross tube. NOTE: Flaps will move slightly beyond fully extended position when actuator is disconnected from cross tube. Support flaps as required. e. Remove bolt securing forward end of actuator to airplane space frame structure;...
Page 207 Flight Controls XL2 Airplane c. Disconnect bolt securing position sensor linkage. d. Remove bolts securing sensor to airframe; remove sensor. 2. FLAP POSITION SENSOR REPLACEMENT: a. Replace sensor and reinstall bolt securing sensor to airframe. b. Reconnect electrical connector to flap position sensor.
Page 208 Fuel XL2 Airplane CHAPTER 28 FUEL P/N 135A-970-006 Chap 28 INITIAL RELEASE - 1 -...
Page 209: Fuel System
Fuel XL2 Airplane Chapter 28 Table of Contents Chapter 28 Table of Contents Chapter 28-00 General Chapter 28-10 Storage Chapter 28-20 Distribution Chapter 28-40 Fuel Indication Fuel System Access Panel Fuel Tank Draining Defueling Fuel Level Sender R&R Gascolator Bowl R&R Gascolator Body R&R...
Page 210 Fuel XL2 Airplane Chapter 28 Fuel Chapter 28-00 GENERAL: This chapter covers only the airframe fuel system (i.e., from the fuel tank to the inlet to the engine fuel system). For information on the engine fuel system, please refer to Chapter 72.
Page 211 Fuel XL2 Airplane Chapter 28-10 STORAGE: The airplane fuel supply is contained in a single tank of 28 US Gallons (106 liters). The tank is of welded aluminum construction and is located in the fuselage directly below the seats. The tank is vented to the atmosphere.
Page 212 Fuel XL2 Airplane Chapter 28-20 DISTRIBUTION: A finger strainer is installed in the tank at a level slightly above the bottom of the fuel sump. A fuel line connects the finger strainer to the gascolator assembly, mounted approximately below the crew seats and accessible for draining through an opening in the fuselage belly fairing.
Page 213 Fuel XL2 Airplane Chapter 28-40 FUEL INDICATION: A capacitive probe installed in the fuel tank provides a signal for the instrument panel mounted fuel contents gauge. FUEL SYSTEM MAINTENANCE ACCESS: Access to the gascolator and electric fuel pump is gained by removing the fuselage belly fairing (see chapter 53).
Page 214 Fuel XL2 Airplane CAUTION: CARRY OUT FUEL DRAINING PROCEDURE IN WELL-VENTILATED AREA FREE OF ANY SOURCE OF IGNITION, INCLUDING ELECTRICAL SWITCHES OR SELF- STARTING ELECTRICAL EQUIPMENT SUCH AS SHOP AIR COMPRESSORS. CAUTION: DISPOSAL OF ALL FUEL IS TO BE CARRIED OUT IN ACCORDANCE WITH LOCAL STANDARD PRACTICES AND PROCEDURES, AS THEY MAY BE DIFFERENT FOR INDIVIDUAL LOCATIONS.
Page 215 Fuel XL2 Airplane Fuel Tank Drain. Gascolator Drain. P/N 135A-970-006 Chap 28-40 INITIAL RELEASE - 3-...
Page 216: Landing Gear
Fuel XL2 Airplane 1. DEFUELING PROCEDURE: a. Ensure all airplane electrical switches are OFF and will remain OFF for duration of procedure. b. Ensure airplane is in a well ventilated location free of any ignition source. c. Ensure fire extinguisher is available for immediate use.
Page 217 Fuel XL2 Airplane o. Drain remaining fuel from gascolator into a separate container. FUEL LEVEL SENDER REMOVAL AND REPLACEMENT: CAUTION: UNLESS REPLACEMENT SENDER UNIT AVAILABLE IMMEDIATE INSTALLATION, HAVE MATERIALS AVAILABLE (HEAVY ALUMINUM FOIL, “TY- WRAP,” TAPE, ETC.) WITH WHICH TO MAKE TEMPORARY VAPOR-TIGHT CLOSURE OF FUEL LEVEL SENDER OPENING.
Page 218 Fuel XL2 Airplane NOTE: Apply Loctite P/N: 39901, anti-seize compound to the first three threads of fuel sender. Take care not to allow compound to contaminate the interior of fuel tank. c. Reinstall fuel level sender by threading back into threaded flange on the top of the fuel tank.
Page 219 Fuel XL2 Airplane c. Place small amount (1 gallon) of fuel in airplane fuel tank and verify there are no leaks. d. Replace fuselage belly fairing. e. Refuel airplane as required. f. Return cockpit fuel valve to ON position. GASCOLATOR BODY REMOVAL AND REPLACEMENT: 1.
Page 220 Fuel XL2 Airplane ELECTRIC FUEL PUMP REMOVAL AND REPLACEMENT: 1. ELECTRIC FUEL PUMP REMOVAL: a. Defuel airplane as described in the defueling procedure. b. Remove fuselage belly fairing. c. Place cockpit fuel valve in OFF position. d. Chock right main and nose landing gear wheels.
Page 221 Fuel XL2 Airplane j. Return BPMS to OFF or AUTO position; remove power from airplane electrical system. k. Replace fuselage belly fairing. l. Refuel airplane as required. COCKPIT FUEL VALVE REMOVAL AND REPLACEMENT: 1. COCKPIT FUEL VALVE REMOVAL: a. Defuel airplane as described in the defueling procedure.
Page 222 Fuel XL2 Airplane e. Position the cockpit fuel valve to ON. NOTE: Red button in handle must be lifted to position to OFF. f. Apply power to airplane electrical switch. Place BPMS in ON position. Verify that pump operates and that no fuel leaks from inlet or outlet of fuel valve.
Page 223 Fuel XL2 Airplane FUEL SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Smell of fuel in airplane loose or defective fuel tighten or repair line fittings Evidence of fuel leaks defective drain valves tighten or repair (stains bottom airplane aft of sump or...
Page 224 Fuel XL2 Airplane APPENDIX CONTENTS: 135A-926-119 Current Revision P/N 135A-970-006 Chap 28-40 INITIAL RELEASE APPENDIX...
Page 225 Indicators XL2 Airplane CHAPTER 31 INDICATORS P/N 135A-970-006 Chap 31 INITIAL RELEASE - 1 -...
Page 226 Indicators XL2 Airplane Chapter 31 Table of Contents Chapter 31 Table of Contents Chapter 31-00 Indicators General Avionics General Indicator R&R Functional Checks Instrument Panel R&R Circuit Breaker Panel R&R Chapter 31-10 Electrical Bonding and Grounding Chapter 31-30 Recorders Chapter 31-60...
Page 227 Indicators XL2 Airplane Chapter 31 Indicators Chapter 31-00 GENERAL: With the exception of the trim position indicator, which is installed on the upper surface of the cockpit center console, all instruments and displays in the airplane are installed on the instrument panel.
Page 228: Lights
Indicators XL2 Airplane Flight and navigation instruments, conforming to a standard layout, are installed in two horizontal rows on the upper left instrument panel. The smaller fuel contents gauge and electric clock are installed to the left of the flight instruments.
Page 229 Indicators XL2 Airplane b. Reapply power to aircraft and perform a functional check. c. Perform a Pitot/Static leak check, if instruments were removed that require this check, ref. 34-10. Troubleshooting, testing and repair of malfunctioning indicators should be performed by qualified maintenance personnel. Functional checks as required are listed in chart below.
Page 230 Indicators XL2 Airplane f. Remove panel from aircraft. 2. REPLACEMENT: a. Reverse the removal order and perform a functional check to Functional Check table. Perform a functional check on all lights and dimming features. CIRCUIT BREAKER PANEL REMOVAL AND REPLACEMENT: 1.
Page 231 Indicators XL2 Airplane Chapter 31-10 Electrical Bonding and Grounding: Each aircraft must have the electrical bonding points checked to ensure compliance with the maximum resistance as stated in the table below. The reference ground is the steel rolling chassis, with all checkpoints relative to the chassis.
Page 232 Indicators XL2 Airplane Measure From: Measure To: Maximum Measured Pass/ Initials/Date Value Value Fail < 0.5 Ω Starboard MPC Ground Bolt Engine mount tab and Firewall mount bolt < 0.5 Ω Port MPC ground bolt Engine mount tab and Firewall mount bolt <...
Page 233 Indicators XL2 Airplane Chapter 31-30 RECORDERS: The VM-1000FX integrated engine instrument display system can record, and display, maximum and minimum engine operating information about each flight. This information can be accessed by successive presses of the rightmost button at the bottom of the engine instrument display panel (“button 5”).
Page 234 Indicators XL2 Airplane Chapter 31-60 CENTRAL DISPLAY SYSTEMS: All engine instruments, as well as voltage and amperage of the airplane electrical system, are combined in the VM1000FX Integrated Engine Instrument Display system. For details, refer to Chapter 77. P/N 135A-970-006...
Page 235 Landing Gear XL2 Airplane CHAPTER 32 LANDING GEAR P/N 135A-970-006 Chap 32 INITIAL RELEASE - 1 -...
Page 236 Landing Gear XL2 Airplane Chapter 32 Table of Contents Chapter 32 Table of Contents Chapter 32-00 General Chapter 32-10 Main Landing Gear Main Landing Gear R&R Nose Landing Gear R&R Chapter 32-40 Wheels and Brakes Wheel R&R (Main and Nose)
Page 237 Landing Gear XL2 Airplane Chapter 32 Landing Gear Chapter 32-00 GENERAL: The airplane has fixed tricycle landing gear. The main landing gear legs are fabricated from single billets of heat-treated aluminum. The nose landing gear is fabricated from solid heat treated spring steel.
Page 238 Landing Gear XL2 Airplane SECTION 32-10 MAIN LANDING GEAR: Each main landing gear leg is fabricated from a single piece of aluminum. The landing gear leg is “rifle drilled” before it is bent to provide an internal passage for brake fluid. Machined surfaces at the top of the gear leg provide a bearing surface for the inboard attachment bolt, one of the two points at which each gear leg is secured to the center fuselage space frame.
Page 239 Landing Gear XL2 Airplane MAIN LANDING GEAR REMOVAL AND REPLACEMENT: 1. MAIN LANDING GEAR REMOVAL: a. Securely chock opposite main gear and nose gear. b. Remove fuselage belly fairing. c. Remove electric fuel boost pump if removing Left main landing gear Ref.
Page 240 Landing Gear XL2 Airplane Main Gear Outboard Frame Attach Point. g. Remove jack from under retention saddle jack point. h. f. Remove outboard main gear attachment bolts and main gear retention saddle; remove gear. 2. MAIN LANDING GEAR REPLACEMENT: a. Install flexible bushing in inboard end of main gear leg.
Page 241 Landing Gear XL2 Airplane e. Tighten inboard main gear attachment bolt to at least 40 +/- 4 in./lbs. plus as much additional rotation as required to bring cotter key hole in line with next available slot on castellated nut; install and secure cotter key.
Page 242 Landing Gear XL2 Airplane NOSE LANDING GEAR REMOVAL AND REPLACEMENT: Nose Gear Installation Forward Fuselage. Centerline Forward Fuselage Nose Gear Installation P/N 135A-970-006 Chap 32-10 INITIAL RELEASE...
Page 243 Landing Gear XL2 Airplane 1. NOSE LANDING GEAR REMOVAL: a. Securely chock both main wheels. b. Ensure propeller blades are in horizontal position. CAUTION: Ensure all electrical switches are OFF before rotating propeller. c. Remove fuselage belly fairing. d. Secure tail stand weighing at least 300 lbs to aft tie-down fitting; lower tail of airplane until nose wheel is just clear of floor.
Page 244 Landing Gear XL2 Airplane Chapter 32-40 WHEELS AND BRAKES: All three wheel assemblies on the airplane are the same, except that brake discs are installed on the two main wheels. The wheels must be disassembled for normal maintenance such as tire and tube replacement or wheel bearing service.
Page 245 Landing Gear XL2 Airplane e. NOSE LANDING GEAR WHEEL: Withdraw axle bolt from nose gear fork, remove wheel and bearing spacers. 2. WHEEL REPLACEMENT (MAIN OR NOSE GEAR): a. Ensure wheel has been properly reassembled after service. Inflate tire to 50 psi (all wheels).
Page 246 Landing Gear XL2 Airplane b. Place tire and tube on wheel half. Ensure tire valve protrudes through access hole in wheel half. c. Place other wheel half in position and insert bolts. Ensure tire tube is not pinched between wheel halves. Bolt heads should be on outboard side of wheel.
Page 247 Landing Gear XL2 Airplane a. Disassemble wheel; remove tire and tube. b. Use solvent and brush to remove all old grease, dirt, etc. from wheel bearings. c. Allow wheel bearings to air-dry on absorbent surface. NOTE: It is permissible to use clean compressed air to dry wheel bearings.
Page 248 Landing Gear XL2 Airplane BRAKES AND BRAKE SERVICE: The airplane uses independent disk brakes on the left and right main landing gear for both deceleration and low-speed (taxi) steering. The brakes are actuated by two master cylinders installed in the chassis center section and controlled by finger levers in the center console.
Page 249 Landing Gear XL2 Airplane f. Reassemble the brake linings in the caliper and replace the caliper in position around the brake disk. Torque the mounting bolts to 95 +/- 5 in/lbs. BRAKE MASTER CYLINDER REMOVAL AND REPLACEMENT: 1. BRAKE MASTER CYLINDER REMOVAL: NOTE: Minor spillage of brake fluid is unavoidable when master cylinders are removed.
Page 250 Landing Gear XL2 Airplane d. Disconnect line from reservoir to master cylinder and cap or plug. e. Remove and discard cotter keys from castellated nuts securing front and rear bolts of master cylinder to cockpit operating lever and to fuselage center section space frame.
Page 251 Landing Gear XL2 Airplane a. Service the brake fluid reservoir to no more than half full with MIL-5606 hydraulic fluid. b. Ensure parking brake is released. c. Connect pressure bleeder to bleed fitting on brake(s) to be bled. d. Open bleed fitting ½ to 1 turn.
Page 252 Landing Gear XL2 Airplane Chapter 32-50 STEERING: The airplane is steered on the ground by differential braking and/or rudder inputs. The nose landing gear is free to caster 85 degrees to either side. Caster stops prevent it from turning further, thus preventing contact between the nose landing gear or its fairing and the propeller.
Page 253 Landing Gear XL2 Airplane Exploded View of Nose Wheel Steering Assembly P/N 135A-970-006 Chap 32-50 INITIAL RELEASE...
Page 254 Landing Gear XL2 Airplane Nose Wheel Steering Assembly NOSE GEAR STEERING SERVICE: a. Chock both main landing gear wheels. b. Fasten tail tie-down to tail stand weighing at least 300 lbs. If a tail stand is not available, place a pad under the tail ensuring the rudder is free to move.
Page 255 Landing Gear XL2 Airplane f. Remove nose gear castor assembly from nose gear leg. Note arrangement of friction / caster stop plates below nose gear bearing housing. Remove roll pin from bearing retaining self locking castle nut. g. Remove nose lock pin inspect for excessive wear every 100 hour inspection and at every annual.
Page 256 Lights XL2 Airplane CHAPTER 33 LIGHTS P/N 135A-970-006 Chap 33 INITIAL RELEASE - 1 -...
Page 257 Lights XL2 Airplane Chapter 33 Table of Contents Chapter 33 Table of Contents Chapter 33-00 General Chapter 33-10 Flight Compartment Instrument Lighting Post Lights Overhead Lights Troubleshooting Chapter 33-40 Exterior Lights Position Lights R&R Anti-Collision Lights R&R Landing Light R&R...
Page 258 Lights XL2 Airplane Chapter 33 Lights Chapter 33-00 GENERAL: The airplane lighting system includes interior (flight compartment) and exterior (position, anti-collision, and landing) lights. P/N 135A-970-006 Chap 33-00 INITIAL RELEASE - 1-...
Page 259 XL2 Airplane Chapter 33-10 FLIGHT COMPARTMENT: Interior (flight compartment) lighting in the Liberty XL-2 includes internal lighting for most instruments, integral backlighting for the Integrated Engine Instrument System display, instrument bezel lights for all installed avionics components, post lighting for instrument panel switches and some indicators, and an overhead light for general illumination and map-reading purposes.
Page 260 Lights XL2 Airplane POST LIGHTING: Extremely low-drain LED post lights are provided for the trim indicator, flap indicator, and panel switch areas. DC Power to illuminate these lights is provided and controlled by the dimmer control. The compass is internally lite.
Page 261 Lights XL2 Airplane INTERIOR LIGHTING TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy All interior lights except defective LIGHTING replace “CB” overhead light circuit breaker inoperative defective wiring repair internal instrument defective INSTRUMENT replace dimmer lights inoperative, post LIGHTS dimmer lights OK...
Page 262 Lights XL2 Airplane Chapter 33-40 EXTERIOR LIGHTING: Exterior lighting on the airplane includes two combination position / strobe (anti- collision) lights installed on the left and right wingtips and a single landing light located in the lower engine cowl. POSITION LIGHTS:...
Page 263 Lights XL2 Airplane c. Remove defective position light bulb. 2. POSITION LIGHT BULB REPLACEMENT: NOTE: Skin oils on the surface of position light bulbs or anti-collision light flash tubes will significantly shorten bulb / flash tube life. Wear latex or vinyl gloves when handling bulbs / flash tubes. Bulbs / flash tubes can be cleaned using 70% isopropyl alcohol swabs (“medical prep”...
Page 264 Lights XL2 Airplane 2. ANTICOLLISION LIGHT FLASH TUBE REPLACEMENT: a. Ensure all electrical switches are OFF and anti-collision light system has been OFF for at least 30 minutes. b. Replace anti-collision light flash tube. c. If necessary, use 70% isopropyl alcohol to clean flash tube.
Page 265 Lights XL2 Airplane EXTERIOR LIGHTING TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Any single position light defective bulb replace bulb inoperative Both (colored and white) 2 defective bulbs replace bulbs position lights on one wing inoperative defective wiring repair connector position...
Page 266: Navigation And Pitot/Static
Navigation and Pitot/Static XL2 Airplane CHAPTER 34 NAVIGATION and PITOT/STATIC P/N 135A-970-006 Chap 34 INITIAL RELEASE - 1 -...
Page 267 Navigation and Pitot/Static XL2 Airplane Chapter 34 Table of Contents Chapter 34 Table of Contents Chapter 34-00 General Chapter 34-10 Flight Environmental Data/Pitot Static Airspeed Indicator Altimeter Vertical Speed Indicator Altitude Transponder OAT Probe OAT Probe R&R Pitot/Static Purging Procedure...
Page 268 Navigation and Pitot/Static XL2 Airplane Chapter 34-50 Dependent Position Instrument R&R Avionics R&R Troubleshooting P/N 135A-970-006 Chap 34 INITIAL RELEASE - 3-...
Page 269: General
Navigation and Pitot/Static XL2 Airplane Chapter 34 Navigation and Pitot/Static Chapter 34-00 GENERAL: Navigation instruments in the airplane include those operated by pitot and/or static pressure (airspeed indicator, altimeter, vertical speed indicator); those operated by gyroscopes (attitude and directional gyros, turn rate indicator); and various avionics subsystems used to determine aircraft position, perform enroute navigation, and assist in approach and landing operations.
Page 270: Flight Environmental Data/Pitot Static
Navigation and Pitot/Static XL2 Airplane Chapter 34-10 FLIGHT ENVIRONMENTAL DATA / PITOT STATIC: Both dynamic (pitot) and static air pressure are sensed by a combination pitot / static probe installed on the underside of the left wing. In the event the primary (under-wing) static source becomes blocked, a...
Page 271: Vertical Speed Indicator
Navigation and Pitot/Static XL2 Airplane VERTICAL SPEED INDICATOR: The vertical speed indicator is a sensitive differential pressure gauge referenced to an air chamber with a small controlled leak to static pressure. It indicates the rate of ascent or descent of the airplane through the atmosphere.
Page 272 Navigation and Pitot/Static XL2 Airplane OAT INDICATOR REMOVE AND REPLACE PROCEDURE: Removal: a. Ensure aircraft electrical power is off. b. Remove the four (4) retaining screws. c. Slide the indicator out of center avionics panel and disconnect electrical connectors. Replacement: a.
Page 273: Pitot/Static Leak Check
Navigation and Pitot/Static XL2 Airplane PITOT / STATIC SYSTEM PURGING PROCEDURE: CAUTION: USE ONLY DRY NITROGEN (NOT “SHOP” COMPRESSED AIR) TO PURGE PITOT AND/OR STATIC LINES. TO AVOID DAMAGE TO INSTRUMENTS, ENSURE THAT PITOT LINE IS DISCONNECTED FROM AIRSPEED INDICATOR AND THAT NITROGEN PURGE SUPPLY IS CONNECTED ONLY TO STATIC LINE FROM INSTRUMENT PANEL TO LEFT WING STATIC SOURCE (I.E., NOT TO STATIC MANIFOLD LINE LEADING TO...
Page 274 Navigation and Pitot/Static XL2 Airplane b. Reversal of tubes can cause damage to the air data instruments they are attached to, check tube orientation. c. The applied pressure (rate of change of pressure) must not exceed the design limits of the equipment under test.
Page 275 Navigation and Pitot/Static XL2 Airplane PITOT / STATIC SYSTEM AND INSTRUMENT TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Airspeed indicator blocked or contaminated drain / purge inaccurate erratic pitot connection (other static instruments pitot or static leak repair defective instrument replace...
Page 276: Attitude And Direction
Navigation and Pitot/Static XL2 Airplane Chapter 34-20 ATTITUDE AND DIRECTION: The airplane’s standard equipment includes a gyroscopic attitude indicator (gyro horizon), a gyroscopic directional indicator (directional gyro), a gyroscopic turn rate indicator (turn coordinator), and a magnetic compass. All of the gyroscopic instruments are electrically operated and are powered by individual 2-amp circuit breakers on the main distribution bus.
Page 277: Directional Gyro
Navigation and Pitot/Static XL2 Airplane DIRECTIONAL GYRO: The directional gyro is installed directly below the attitude gyro and indicates the airplane’s heading. Due to the primary trait of gyroscopic rigidity in space, the directional gyro provides much more stable indications in accelerated or turning flight, or in turbulence, than the magnetic compass.
Page 278: Magnetic Compass And
Navigation and Pitot/Static XL2 Airplane A bank indicator (“inclinometer”), consisting of a metal ball moving in a curved glass tube filled with damping liquid, indicates the airplane bank attitude relative to the resultant “local vertical” determined by the airplane’s rate of turn. No power is required for operation of the inclinometer.
Page 279 Navigation and Pitot/Static XL2 Airplane Using hand signals, the maintenance technician signals the person in the cockpit to make additional adjustments to align the aircraft with the master compass. Once aligned on the heading, the person in the cockpit runs the engine to approximately 1,700 rpm to duplicate the aircraft’s magnetic field and then he/she reads the compass.
Page 280 Navigation and Pitot/Static XL2 Airplane View of compass showing correction holes. P/N 135A-970-006 Chap 34-20 INITIAL RELEASE...
Page 281 Navigation and Pitot/Static XL2 Airplane Compass Correction Card Fitting: The correction card, supplied with the compass, is to be fitted to the underside of the compass. Withdraw the lower housing as shown and clip the card into place. Replace the lower housing when finished. Make sure it clips into place.
Page 282 Navigation and Pitot/Static XL2 Airplane Magnetic Compass Calibration Form Aircraft Tail Number: Date: Radios ON Radios OFF Master Compass Aircraft Compass Master Compass Aircraft Compass Magnetic Compass Calibration Form P/N 135A-970-006 Chap 34-20 INITIAL RELEASE...
Page 283 Navigation and Pitot/Static XL2 Airplane ATTITUDE AND DIRECTION INSTRUMENT TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Attitude gyro inoperative defective attitude gyro replace circuit breaker (OFF flag visible) circuit breaker defective instrument replace instrument defective wiring repair Attitude gyro indications defective attitude gyro...
Page 284 Navigation and Pitot/Static XL2 Airplane Chapter 34-30 LANDING AND TAXI AIDS: Landing aids in the airplane include localizer, glideslope, and marker beacon receivers and their associated displays. Localizer and glide-slope receivers and their displays are incorporated with dependent position determining displays and are discussed in the applicable sub/SECTION.
Page 285 Navigation and Pitot/Static XL2 Airplane Chapter 34-50 DEPENDENT POSITION DETERMINING: The airplane may be equipped with various optional avionics installations offering dependent position determining and approach and landing aid functions based on signals from ground stations (VOR, ILS) and the satellite-based Global Positioning System (GPS).
Page 286 Navigation and Pitot/Static XL2 Airplane b. Reinstall instrument. c. Reconnect pneumatic and/or electrical connectors, ensuring correct connection (especially important for identical-appearing pneumatic connections). d. Perform functional check on replaced instruments before replacing instrument panel or glare-shield. AVIONICS COMPONENT REMOVAL AND REPLACEMENT PROCEDURES (GENERAL): 1.
Page 287 Navigation and Pitot/Static XL2 Airplane g. Insert hex key and turn clockwise to engage mounting claw, pull unit into panel, and seat connectors. Stop when component is seated in mounting tray or at any time if excessive resistance is encountered.
Page 288: Structures
Standard Practices - Structures XL2 Airplane CHAPTER 51 STANDARD PRACTICES - STRUCTURES P/N 135A-970-006 Chap 51 INITIAL RELEASE - 1 -...
Page 289 Standard Practices - Structures XL2 Airplane Chapter 51 Table of Contents Chapter 51 Table of Contents Chapter 51-00 General Damage Classification Type 1 Damage Type 2 Damage Type 3 Damage Type 4 Damage Chapter 51-10 Repairs Necessitating Liberty Aerospace Liaison...
Page 290: General
(significant skin damage, any damage to underlying structures such as spars, ribs, stringers, etc.) should be referred to Liberty Aerospace Customer Service, for determination and the proper drawings. Repairs to composite components such as the fuselage or cowling may be more problematical due to the original method of manufacture for these components.
Page 291: Damage Classification
This type of damage requires partial or complete reconstruction of parts or repairs of large areas. Repairs shall be performed only by Liberty Aerospace, or by a facility specifically authorized by Liberty Aerospace for Type 1 repairs. TYPE 2- DAMAGE: Damage inflicted to primary or secondary structure.
Page 292: Type 3 Damage
Damage is classified as Type 2 if it has the potential to affect the structural integrity of the aircraft in flight. Repairs shall be performed by a facility specifically authorized by Liberty Aerospace for Type 2 repairs. Composite damage may be repaired by a facility specifically authorized by Liberty Aerospace for composite repairs.
Page 293: Repairs Necessitating Liberty
Also the structure may be weakened by the extensive removal and repair of load bearing skin. REPAIRS INVOLVING FABRICATED GLASS FIBER COMPONENTS: In a repair of this nature, Liberty Aerospace drawings of the area involved should be obtained. REPAIRS INVOLVING GLASS FIBER ROVINGS: Generally these areas may be repaired by Liberty Aerospace only.
Page 294 Standard Practices - Structures XL2 Airplane Bond defects include: • Disbonds (separation between bonded adherents). • Inclusions (foreign matter in bondline). • Porosity (frequent small voids in bondline). • Lack of adhesive (visible due to no squeeze-out). When there is a doubt regarding classifying a potential defect as a defect, it should be treated as a defect.
Page 295: Tap Testing
Standard Practices - Structures XL2 Airplane INSPECTION CLASSIFICATIONS The aircraft fuselage and all composite components have been inspected prior to release, the method used was tap testing. At the time of aircraft release no ultrasound/radiographic testing was performed, but is brought out in this manual as an alternate means of testing composite materials for disbonding.
Page 296 DAT is 1.0 ft , then add up all defect sizes within a given square foot; if the total exceeds 1.0 inch than the component must be submitted to Liberty Aerospace for determination. P/N 135A-970-006 Chap 51-10 INITIAL RELEASE...
Page 297 Standard Practices - Structures XL2 Airplane Laminate Defect Size Definition Examples Example Application of Laminate DAT The laminate defect size definition examples show how the DAT is used to determine cumulative defects. After all defects are identified, move the DAT “window”...
Page 298 Standard Practices - Structures XL2 Airplane Laminate Inspection Classifications Laminate Minimum Required Inspection Classification Inspection type not specified 100% visual + 100% NDI ultrasound 100% visual + 100% NDI tap testing 100% visual only Reserved Reserved Notes: The classification “NS” means that the inspection method is not specified.
Page 299: Inspection Requirements
Standard Practices - Structures XL2 Airplane INSPECTION REQUIREMENTS: FUSELAGE AND INTEGRAL VERTICAL STABILIZER: BONDS: Bonds must meet the requirements of the applicable engineering drawing and material and process specifications. In addition, bonds must be inspected for defects according to their classification as presented in the table below.
Page 300 Standard Practices - Structures XL2 Airplane SINGLE SKIN REPAIR This data sheet describes the repair techniques for single skin damage, where the damage is accessible from one side only. a. The edges around the hole to be repaired should be chamfered at an angle of 1:30 minimum.
Page 301 Standard Practices - Structures XL2 Airplane l. When the finishing layer has hardened, remove the polythene and inspect. m. The repair is now finished. P/N 135A-970-006 Chap 51-10 INITIAL RELEASE...
Page 302 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -10-...
Page 303 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -11-...
Page 304 Standard Practices - Structures XL2 Airplane SINGLE SKIN REPAIR This procedure describes the repair of single skin damage when it is readily accessible from both sides. A satisfactory repair could be made from the outside; however, because of the easy accessibility the repair may be laminated up from the inside against a backing piece that is removed after the repair has hardened.
Page 305 Standard Practices - Structures XL2 Airplane i. Inspect the final cloth layer. j. The backing piece is now released and the repair is finished. P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -13-...
Page 306 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -14-...
Page 307: Sandwich Structure Repair
Standard Practices - Structures XL2 Airplane SANDWICH STRUCTURE REPAIR: DAMAGE TO OUTER SKIN ONLY: This procedure covers the repair of damage to the outer skin of a sandwich structure (Fig. 1). a. The damaged glass fiber should be cut back and also all core damage cut out (Fig.
Page 308 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -16-...
Page 309 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -17-...
Page 310: Minor Damage To Both Skins
Standard Practices - Structures XL2 Airplane MINOR DAMAGE TO BOTH SKINS This procedure describes the method of repair to a sandwich structure when both skins have only minor damage, (Fig. 1). a. The damage to both skins must be cut away until sound material is reached.
Page 311 Standard Practices - Structures XL2 Airplane l. Surrounding 50mm of gel coat sanded off. m. The finishing layer of cloth is now laminated over the repair and polythene smoothed over the wet laminate, (Fig. 7). n. When the finishing layer has hardened, remove the polythene and inspect.
Page 312 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -20-...
Page 313 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -21-...
Page 314 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -22-...
Page 315 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -23-...
Page 316 Standard Practices - Structures XL2 Airplane MAJOR DAMAGE TO BOTH SKINS This procedure describes the method of repair to a sandwich structure when both skins have major damage. a. The damage to both skins must be cut away until sound material is reached.
Page 317 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -25-...
Page 318 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -26-...
Page 319 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -27-...
Page 320: Sandwich Structure Repair Major Damage To Both Skins Alternative
Standard Practices - Structures XL2 Airplane SANDWICH STRUCTURE REPAIR-MAJOR DAMAGE TO BOTH SKINS- ALTERNATIVE: a. The damage to both skins must be cut away until sound material is reached. The hole should be prepared as shown in Fig. 1. The edges should be chamfered at 1:30 minimum and 25mm of the inner skin inner surface around the hole lightly abraded.
Page 321 Standard Practices - Structures XL2 Airplane P/N 135A-970-006 Chap 51-10 INITIAL RELEASE -29-...
Page 322: Inspection Of Glass Fiber Repairs
Standard Practices - Structures XL2 Airplane INSPECTION OF GLASS FIBER REPAIRS Whenever freshly laminated glass fiber has set hard it should be inspected for defects before any further work is done upon it. The points to be inspected are described here.
Page 323 Standard Practices - Structures XL2 Airplane f. The gel coat is now sanded smooth, and the surface should be free from imperfections and have a good depth of color. If further coats are required paragraph ”c” and “d” should be repeated.
Page 324 Standard Practices - Structures XL2 Airplane ALUMINUM REPAIR: NOTE: All precautions should be taken as to local requirements for the handling of chemicals and the disposal of chemically soaked rags, wiping cloths or materials used in the preparation and repair of the surface.
Page 325 Doors XL2 Airplane CHAPTER 52 DOORS P/N 135A-970-006 Chap 52 INITIAL RELEASE - 1 -...
Page 326 Doors XL2 Airplane Chapter 52 Table of Contents Chapter 52 Table of Contents Chapter 52-00 General Chapter 52-10 Passenger/Crew Doors Doors R&R Door Seal R&R Gas Spring R&R Troubleshooting P/N 135A-970-006 Chap 52 INITIAL RELEASE - 2-...
Page 327 Doors XL2 Airplane Chapter 52 Doors Chapter 52-00 GENERAL: The airplane has two large “gull wing” or swing-up doors to provide pilot and passenger access to the flight compartment. These doors also provide access to the baggage area behind the seats; no separate baggage door is provided.
Page 328: Fuselage
Doors XL2 Airplane Chapter 52-10 PASSENGER / CREW DOORS A large door on each side provides passenger and crew access. The doors are top-hinged to the upper fuselage and open upward. When open, each door is supported in the open position by a gas cylinder (“gas spring”). The gas spring also contains oil which provides a dampening function as the door approaches the fully-opened position.
Page 329 Doors XL2 Airplane NOTE: If any difficulty is experienced opening door latches on the ground, upward pressure from the door seal material may be sufficient to engage these “safety hooks.” Maintain slight downward (closing) pressure on the door while rotating the internal or external door handle to the open position.
Page 330 Doors XL2 Airplane DOOR REMOVAL AND REPLACEMENT: 1. DOOR REMOVAL: a. Fully open door. b. Remove upholstery trim from cabin headliner to reveal four door hinge pin openings. c. Support door in open position and disconnect gas cylinder end from door.
Page 331 2. GAS SPRING REPLACEMENT: CAUTION: REPLACE GAS SPRING ONLY WITH EXACT DUPLICATE PART NUMBER OBTAINED FROM LIBERTY AEROSPACE, INC. USE OF “GENERIC” REPLACEMENT GAS SPRINGS MAY CAUSE DAMAGE TO DOOR OR DOORFRAME STRUCTURE a. Support door in open position. b. Snap gas spring cylinder end onto fitting on door.
Page 332 Doors XL2 Airplane DOOR TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Door does not latch latch(es) or linkage out of adjust properly; door latches adjustment difficult to engage latches need lubrication Lubricate with Corrosion X Door latches OK but excessive pressure from...
Page 333 Fuselage XL2 Airplane CHAPTER 53 FUSELAGE P/N 135A-970-006 Chap 53 INITIAL RELEASE - 1 -...
Page 334 Fuselage XL2 Airplane Chapter 53 Table of Contents Chapter 53 Table of Contents Chapter 53-00 General Fuselage R&R Chapter 53-10 Main Frame Chapter 53-20 Plates/Panels/Skin Belly Panel R&R Chapter 53-40 Attach Fittings P/N 135A-970-006 Chap 53 INITIAL RELEASE - 2-...
Page 335 Fuselage XL2 Airplane Chapter 53 Fuselage Chapter 53-00 GENERAL: The airplane fuselage consists of a center fuselage space frame or “chassis” assembly assembled from welded steel tubing, while the remainder of the fuselage is fabricated from composite material. With the exception of forces...
Page 336 Fuselage XL2 Airplane Access panels are provided in internal structural elements as required to facilitate maintenance. The aft baggage compartment closeout is a removable, nonstructural component to allow access to the interior of the aft fuselage and components located there including the aircraft batteries, electrical system components, and rudder and stabilator control pushrods.
Page 337 Fuselage XL2 Airplane i. Disconnect all connectors from fuselage to rolling chassis. j. Ensure that a large padded area is available once fuselage is lowered. k. Remove fuselage to rolling chassis bolts. l. Using strap lifting method in Ch. 7, lift fuselage from rolling chassis and place on pads.
Page 338 Fuselage XL2 Airplane Chapter 53-10 MAIN FRAME: Most significant ground and flight loads are accepted and transmitted by the central space frame. The landing gear is bolted to its underside, while the welded steel engine mounts bolts to its forward fittings. Heavy wing box fittings on each side accept corresponding spar fittings on the wing roots, where they are secured by pins positioned by electric actuators (see chapter 57).
Page 339 Fuselage XL2 Airplane The aileron control linkages from the cockpit control sticks terminate in left and right aileron quick connect assemblies attached to the space frame. Corresponding assemblies on the wings automatically mate with the quick connect assemblies when the wings are installed.
Page 340 Fuselage XL2 Airplane Chapter 53-20 PLATES / SKIN: Various access plates are provided to allow maintenance of components inside the fuselage. P/N 135A-970-006 Chap 53-20 INITIAL RELEASE...
Page 341 Fuselage XL2 Airplane The most significant of these is the fuselage belly fairing, which provides access to the entire interior of the fuselage center section space frame. It is secured by “Cam-Lock” fasteners around its periphery. P/N 135A-970-006 Chap 53-20...
Page 342 Fuselage XL2 Airplane FUSELAGE BELLY FAIRING REMOVAL AND REPLACEMENT: Recommended equipment: • A small, padded stand capable of supporting the weight of the fuselage belly fairing. Adjustable height is desirable but not absolutely necessary. A toolbox, bucket, or a mechanics creeper, and some foam rubber or cloth padding is sufficient.
Page 343 Fuselage XL2 Airplane a. Place padded support under approximate center of fuselage opening. b. Place fuselage belly fairing on support. c. Align belly fairing with opening. d. Insert and fasten (4) Cam-Lock fasteners at corners of fuselage belly fairing. e. Fasten remaining Cam-Lock fasteners.
Page 344 Fuselage XL2 Airplane Chapter 53-40 ATTACH FITTINGS Attachment fittings for the left and right main landing gear are integral to the fuselage center section weld. They are bolted in two separate locations on the main chassis. The upper is bolted through the main frames, while the lower is captured by a saddle clamp and bolted.
Page 345: Stabilizers
Stabilizers XL2 Airplane CHAPTER 55 STABILIZERS P/N 135A-970-006 Chap 55 INITIAL RELEASE - 1 -...
Page 346 Stabilizers XL2 Airplane Chapter 55 Table of Contents Chapter 55 Table of Contents Chapter 55-00 General Chapter 55-10 Horizontal Stabilator Horizontal Stabilator R&R Stabilator Attach Lug R&R Tail Plane Mass Balance Arm R&R Chapter 55-30 Vertical Stabilator Chapter 55-40 Rudder Rudder R&R...
Page 347 Stabilizers XL2 Airplane Chapter 55 Stabilizers Chapter 55-00 GENERAL: The control surfaces and stabilizers of the airplane are of conventional aluminum structure. The all-flying horizontal stabilizers (“stabilators”) provide pitch control. Ailerons installed in the wings provide roll control, while a rudder hinged to the rear spar of the vertical stabilizer (fin) provides yaw control.
Page 348 Stabilizers XL2 Airplane Chapter 55-10 HORIZONTAL STABILIZERS: All-flying “stabilators” are used, rather than the conventional arrangement of a fixed horizontal stabilizer and hinged elevator. The stabilators are of conventional aluminum construction, incorporating forward and rear spars, ribs, and skins. The anti-servo tabs are hinged to the top rear of the stabilators.
Page 349 Stabilizers XL2 Airplane HORIZONTAL STABILATOR (TAILPLANE) REMOVAL AND REPLACEMENT: 1. STABILATOR REMOVAL: a. Remove and discard cotter pin from castellated nut on the stabilator attach bolt. b. Remove castellated nut and sleeve. c. Remove bolt (may be necessary to drive out from below by tapping gently with appropriately sized drift punch).
Page 350 Stabilizers XL2 Airplane REPLACEMENT: a. Reverse the above steps. b. Torque the retaining screws to 50 in/lbs. TAIL PLANE MASS BALANCE ARM REMOVE AND REPLACEMENT: REMOVE: a. Support the tail of the airplane with a padded stand. b. Remove left and right tail planes Ref 55-10.
Page 351 Stabilizers XL2 Airplane h. Remove and discard cotter pins from tail plane mass balance arm bolts. i. Loosen bolts retaining the tail plane mass balance arm to tail plane torque tube individually bag bolts, washers, and nuts, label according to location of removal.
Page 352 Stabilizers XL2 Airplane j. Check that tail plane moves in the proper direction based on control inputs, moving the control stick forward the tail plane will move trailing edge down. k. Re-install baggage area closeout. P/N 135A-970-006 Chap 55-10 INITIAL RELEASE...
Page 353 Stabilizers XL2 Airplane Chapter 55-30 VERTICAL STABILIZER The vertical stabilizer incorporates composite skins contiguous with the composite upper fuselage molding and composite (carbon fiber) internal structure including forward and rear spars and ribs. There is no removal or replacement for this structure.
Page 354 Stabilizers XL2 Airplane SECTION 55-40 RUDDER: The rudder is of conventional aluminum construction and includes a forward spar, ribs, and skin. A single full-length piano hinge on the right side of the forward spar secures the rudder to the rear spar of the vertical stabilizer. Fittings attached to the rudder forward spar transmit operating loads from the rudder control pushrod.
Page 355 Stabilizers XL2 Airplane RUDDER REMOVAL AND REPLACEMENT: 1. RUDDER REMOVAL: a. Deflect rudder fully to the right. b. Remove bolts securing the rudder hinge to the right side of the vertical fin, note that the hinge remains with the rudder.
Page 356: Windows
Windows XL2 Airplane CHAPTER 56 WINDOWS P/N 135A-970-006 Chap 56 INITIAL RELEASE - 1 -...
Page 357 Windows XL2 Airplane Chapter 56 Table of Contents Chapter 56 Table of Contents Chapter 56-00 General Window/Windshield Guidelines Window/Windshield R&R Window/Windshield Trimming Technique P/N 135A-970-006 Chap 56 INITIAL RELEASE - 2-...
Page 358 Windows XL2 Airplane Chapter 56 Windows Chapter 56-00 GENERAL: The airplane windows are integral to the flight compartment; there is no separate passenger area. All transparencies are fabricated from acrylic plastic material. Transparencies include the molded acrylic windshield and large side windows integral to each cabin door.
Page 359 Windows XL2 Airplane PERMANENT REPAIRS: Windshields or side windows with small cracks that affect only the appearance rather than the airworthiness of a sheet, may be repaired by first stop-drilling the ends of the crack with a # 30 or a 1/8-inch drill. Then use a hypodermic syringe and needle to fill the crack with polymerizable cement such as PS-30 or Weld-On 40, and allow capillary action to fill the crack completely.
Page 360 USE ANY CLEANING PRODUCT CONTAINING ABRASIVES OF ANY KIND. WINDSHIELD / WINDOW REPLACEMENT: In the event a transparency (windshield or window), is damaged (scratched, cracked, crazed, etc.), a replacement can be obtained from Liberty Aerospace or an authorized supplier. Replacements may be shipped oversized and may require trimming for correct fit.
Page 361 Windows XL2 Airplane WINDSHIELD / WINDOW TRIMMING TECHNIQUE: • Contact Liberty Aerospace windshield/window replacement procedures. INSTALLATION OF REPLACEMENT WINDSHIELD / WINDOW: • Contact Liberty Aerospace windshield/window replacement procedures. P/N 135A-970-006 Chap 56-00 INITIAL RELEASE...
Page 362: Wings
Wings XL2 Airplane CHAPTER 57 WINGS P/N 135A-970-006 Chap 57 INITIAL RELEASE - 1 -...
Page 363 Wings XL2 Airplane Chapter 57 Table of Contents Chapter 57 Table of Contents Chapter 57-00 General Chapter 57-10 Main Frame Chapter 57-20 Auxiliary Structure Wing Tip R&R Chapter 57-30 Plates / Skins Chapter 57-40 Attachment Fittings Wing R&R Wing root fittings...
Page 364 Maintenance procedures covered in this manual are limited to removal and replacement of entire wing(s). Liberty Aerospace, at this time has no published a repair procedure. When this procedure is compiled and approved, it will be come a part of this manual. If damage is incurred to the aircraft before that time, contact Customer service at Liberty Aerospace for assistance.
Page 365 Liberty Aerospace Customer Service or qualified service personnel. 3. Replacement – Any damage that is extensive or major enough, where repair costs exceed that of replacement costs. Contact Liberty Aerospace Customer Service. P/N 135A-970-006 Chap 57-00...
Page 366 Wings XL2 Airplane Chapter 57-10 MAIN FRAME: The wing main frame includes a built-up aluminum main spar, leading edge spar, and rear spar. A total of eleven ribs (including root and tip ribs) are secured to the spars. There are eight ribs between the root and the junction of the flap and the aileron, with three further ribs between this point and the outboard end of the aileron.
Page 367 Wings XL2 Airplane Chapter 57-20 AUXILIARY STRUCTURE: The wing leading and trailing edges are integral to the wing skin. The composite wing tip is secured to the outermost wing rib by screws and nut- plates and is easily removable. WING TIP REMOVAL AND REPLACEMENT PROCEDURE: 1.
Page 368 Wings XL2 Airplane Chapter 57-30 PLATES/SKIN: The wing skins are wrapped around the internal structure and are riveted to the ribs, stringers, and spars. Two round access panels are provided on the lower surface of each wing, to provide access to the aileron bell-crank and pushrods for maintenance. The access panels are secured by three screws each to nut-plates attached to doublers around the access panel openings.
Page 369 Wings XL2 Airplane Chapter 57-40 ATTACH FITTINGS: Three heavy fittings secure each wing to the fuselage. Upper and lower main spar fittings transmit primary lift and secondary drag loads to the fuselage center section chassis. A fitting on the rear spar transmits primary drag and secondary lift loads to the fuselage center section chassis.
Page 370 Wings XL2 Airplane • Wing pin actuator cable, contact Liberty Aerospace for details. • Source of 12vdc electrical power (min. 10 amp capacity). NOTE: This procedure requires at least two, and preferably three, people. Each wing panel is heavy. NOTE: Using calipers measure the outside diameter of the wing attach pins and ensure that they are not more that 10% less of the inside diameter of the wing attach points.
Page 371 Pull wing away from fuselage and place on padded supports for further maintenance as required. j. Inspect the wing pins as to the note above. For corrosion contact Liberty Aerospace Customer Service for instruction on correction. CAUTION:...
Page 372 Wings XL2 Airplane NOTE: Listen for actuator operation; actuator motor will continue to operate. g. Return actuator cable switch to OFF position; disconnect cable from actuator connector and 12vdc power source. h. When wing pins are fully seated ensure that the chamfered surface and approximately 1/16”...
Page 373 Wings XL2 Airplane Chapter 57-50 FLIGHT SURFACES: NOTE: This subsection describes the structure of flight surfaces only. For flight surface removal / reinstallation procedures, refer to Chapter 27. Ailerons: Cut – Away View of Aileron Each aileron comprises a front spar, eight ribs, a one-piece skin, two hinges, and two mass balance assemblies.
Page 374 Wings XL2 Airplane Each flap comprises a spar, six ribs, and two skins. One skin forms the flap’s leading edge and is wrapped from the spar around the leading edge ribs; the other forms the remainder of the flap, is folded at the flap trailing edge, and is also secured at top and bottom to the flap spar.
Page 375 Propeller XL2 Airplane CHAPTER 61 PROPELLER P/N 135A-970-006 Chap 61 INITIAL RELEASE - 1 -...
Page 376 Propeller XL2 Airplane Chapter 61 Table of Contents Chapter 61 Table of Contents Chapter 61-00 General Chapter 61-10 Propeller Assembly Propeller R&R Propeller Bolt Torque Procedure Repair of Cosmetic Damage Troubleshooting P/N 135A-970-006 Chap 61 INITIAL RELEASE - 2-...
Page 377 69 x 63 inches. Differing pitches to optimize the airplane’s performance for “climb” or “cruise” operations in varying conditions may be authorized by Liberty Aerospace Inc. Maintenance operations covered in this manual are limited to propeller and spinner removal and replacement, propeller bolt torque checks, and repair to minor (“cosmetic”) damage to the propeller finish.
Page 378 Propeller XL2 Airplane Chapter 61-10 PROPELLER ASSEMBLY: The propeller is equipped with a spinner manufactured of composite materials and secured to front and rear composite spinner mounting plates (“spinner bulkheads”). Exploded View of Propeller/Spinner Installation P/N 135A-970-006 Chap 61-10 INITIAL RELEASE...
Page 379 “clocking” of propeller to crankshaft. If required refer to Liberty Aerospace drawing number 135A-50-015, ref. note: number 24. states; 1. “With engine cylinder #4 at top dead center, Install propeller and...
Page 380 Propeller XL2 Airplane g. Rotate propeller CCW to horizontal position and place padded support under propeller blade to technician’s left (airplane’s right side) to restrain against further CCW movement. h. Loosen propeller mounting bolts in “criss-cross” pattern until all six bolts are free (i.e., loosen first bolt;...
Page 381 Propeller XL2 Airplane NOTE: If orientation markings have been lost, correct “clocking” of spinner mounting plates is with two screw holes and nut-plates at approximate leading and trailing edges of each propeller blade. If screw hole/nut-plate is approximately at center of propeller blade, remove and reposition spinner mounting plate(s).
Page 382 Propeller XL2 Airplane i. Reinstall spinner using screws in front and rear spinner mounting plates. Observe markings for proper orientation. If propeller has been dynamically balanced, replace additional washers under rear spinner screws in same number and type as they were removed and marked.
Page 383 Propeller XL2 Airplane 1. PROPELLER BOLT TORQUING TECHNIQUE (installation or reinstallation): Required equipment: • Calibrated “dial” type torque wrench with appropriate socket. • Safety wire, safety wire twisting pliers (Assumes steps for propeller reinstallation have been followed per procedure given above).
Page 384 Propeller XL2 Airplane g. Use torque wrench to value specified by propeller manufacturer plus value recorded in step c above. h. Tighten bolts to this final torque value in “criss cross” pattern. i. Perform final torque check for all bolts.
Page 385 Propeller XL2 Airplane i. Reinstall safety wire in approved pattern. j. Reinstall spinner. REPAIR OF “COSMETIC” DAMAGE TO PROPELLER: • “Cosmetic” damage is defined as abrasions or scratches to the paint which do not penetrate to the underlying wood; or small scratches or abrasions through which the underlying wood is visible, but in which it can be determined that there is no damage to the wood itself.
Page 386 Propeller XL2 Airplane PROPELLER TROUBLESHOOTING CHART: Complaint Probable cause Remedy “Cosmetic” damage sand, foreign objects, etc. repair procedure propeller finish given above Unusual vibration Incorrect propeller bolt check torque torque (may cause procedure given above incorrect propeller blade “track”). Damaged propeller hub remove propeller, inspect front and rear hub faces.
Page 387 Standard Practices - Engine XL2 Airplane CHAPTER 70 STANDARD PRACTICES - ENGINE P/N 135A-970-006 Chap 70 INITIAL RELEASE - 1 -...
Page 388 Standard Practices - Engine XL2 Airplane Chapter 70 Table of Contents Chapter 70 Table of Contents Chapter 70-00 General Adhesives Application Digital Volt Meter usage Securing Electrical Harness Low Voltage Harness EGT R&R P/N 135A-970-006 Chap 70 INITIAL RELEASE - 2-...
Page 389 Standard Practices - Engine XL2 Airplane Chapter 70 Standard Practices - Engine Chapter 70-00 GENERAL: This chapter describes standard practices to be employed in maintenance procedures on the Teledyne Continental Motors IOF-240 engine installed on the aircraft. In addition, information is provided on specific procedures for field splicing of the Low Voltage Harness employed on this engine.
Page 390 Standard Practices - Engine XL2 Airplane If anything is dropped into the engine stop work immediately and remove it. Ensure all parts are thoroughly cleaned, properly protected from dust and corrosion, and properly stored until assembly. Ensure replacement nonmetallic and metallic parts show no sign of storage deterioration.
Page 391 Standard Practices - Engine XL2 Airplane Voltage measurements: All voltage measurements made while servicing the FADEC system will be DC. Most will be from a positive voltage point to airframe ground. Some voltage measurements will be made between specified points within the FADEC low voltage harness, not directly to aircraft ground.
Page 392 Standard Practices - Engine XL2 Airplane Avoid routing or securing the harness in a manner that could allow chafing while in service. Inspect all proposed harness routing giving consideration to normal movement of the various parts to which the harness will be secured, or with which it could come in contact.
Page 393 Standard Practices - Engine XL2 Airplane NOTE: There are two types of wire splice kits, one for EGT sensors and wiring (metal over braid outer jacket) and a second type for all other sensors and conductors. This is necessary because the EGT sensors are K-type thermocouples, with chromel and alumel conductors.
Page 394 Standard Practices - Engine XL2 Airplane CAUTION: FAILURE TO USE EGT SPLICE KIT FOR EGT WIRE REPAIR OR SENSOR REPLACEMENT WILL RESULT IN ABNORMAL ENGINE OPERATION AND MAY CAUSE ENGINE DAMAGE. • Cut and remove all wire ties securing section of engine harness to be serviced.
Page 395 Standard Practices - Engine XL2 Airplane • Cut the sensor wire with the trace 1 inch from the end of the sensor lead. • Strip both wires 3/16” from the cut ends. Engine harness lead wire prep: • Use same technique as described above, except cut the engine harness lead wire without the trace 1 inch from the end of the harness lead.
Page 396 Standard Practices - Engine XL2 Airplane EGT SENSOR REPLACEMENT OR LEAD REPAIR: • The technique to splice the EGT lead wires (either to replace an EGT probe or to repair the harness) is essentially similar to that given above. However, the EGT wires have both an external overbraid jacket and an internal insulating jacket which must be stripped and trimmed separately.
Page 397 Standard Practices - Engine XL2 Airplane • Insert and crimp the long wires into the splices installed in the previous step, making sure that the yellow wire is inserted into the splice with the white strip and the red wire is inserted into the splice with the red stripe.
Page 398: Power Plant
Power Plant XL2 Airplane CHAPTER 71 POWER PLANT P/N 135A-970-006 Chap 71 INITIAL RELEASE - 1 -...
Page 399: Engine
Power Plant XL2 Airplane Chapter 71 Table of Contents Chapter 71 Table of Contents Chapter 71-00 General Engine Operational Check Engine R&R Chapter 71-10 Cowling R&R Chapter 71-20 Engine Mounts Chapter 71-30 Firewall Blanket Firewall Blanket R&R Chapter 71-50 Electrical Harness...
Page 400 B – Model designation indicating that the engine is designed for use with a fixed- pitch propeller, with a doweled six bolt hole propeller flange and no provision for a hydraulic propeller governor. 4 – Specific configuration of accessories as supplied to Liberty Aerospace, Inc., for use on the airplane. P/N 135A-970-006...
Page 401 Power Plant XL2 Airplane Because of the nature and complexity of the FADEC system, procedures covered in this maintenance manual include routine line servicing, replenishment of operating fluids, and replacement of “consumable” components such as spark plugs only. Detailed information and procedures covering maintenance and...
Page 402 Power Plant XL2 Airplane ENGINE START, RUN-UP, AND SHUTDOWN: ENGINE OPERATIONAL CHECK: An engine operational check must be performed prior to 50 and 100 hour engine inspections. Start the engine following POH/AFM procedures. Allow engine to warm up until oil temperature is 100 deg. F or higher.
Page 403 Power Plant XL2 Airplane WARNING: ABSENCE OF RPM DROP WHEN CHECKING FADEC CHANNELS INDICATES A MALFUNCTION IN ONE OF THE MPC PROCESSORS OR HIGH VOLTAGE COIL ASSEMBLY AND WILL RESULT IN IMPROPER ENGINE OPERATION. THIS TYPE OF MALFUNCTION MUST CORRECTED...
Page 404 Power Plant XL2 Airplane l. Disconnect landing light lead. m. Disconnect (2) Low Voltage Harness connectors at firewall (Cannon plugs). n. Disconnect throttle and alternate air operating linkages. o. Disconnect oil cooler from firewall. p. Attach hoist to lifting eye at top of crankcase.
Page 405 Power Plant XL2 Airplane Chapter 71-10 COWLING: The airplane uses a two-piece (upper and lower) cowling of composite construction. The upper cowling incorporates a small door to allow oil level checks and oil replenishment without the need to remove the cowling.
Page 406 Power Plant XL2 Airplane e. Fasten all cam locks securing upper cowling to fuselage and to lower cowling. CAUTION: OPERATE ENGINE ONLY WITH BOTH UPPER AND LOWER COWLING INSTALLED AND SECURED, OR WITH BOTH UPPER AND LOWER COWLING REMOVED (DO NOT OPERATE WITH EITHER UPPER OR LOWER COWLING INSTALLED ALONE).
Page 407 Power Plant XL2 Airplane Chapter 71-20 ENGINE MOUNTS: A welded steel tube structure secures the engine to the fuselage center section space frame. It is attached to the space frame by four bolts with nuts and washers. If necessary, the engine mount can be removed from the space frame.
Page 408 Power Plant XL2 Airplane Exploded View of Engine Mounts Firewall and fuselage are not shown for clarification. P/N 135A-970-006 Chap 71-20 INITIAL RELEASE...
Page 409 FIREWALL BLANKET: The removable engine firewall blanket is a fireproof barrier made specifically for the XL2 airplane. The blanket is constructed of silicone coated, aluminized, glass cloth. The layers are sealed on the edges with high temperature red RTV. P/N 135A-970-006...
Page 410 Power Plant XL2 Airplane The firewall blanket is to be inspected for general condition. Any abnormalities i.e.: tears, discoloration, or evidence of damage will be addressed to Liberty Aerospace Customer Service. FIREWALL BLANKET REMOVAL AND REPLACEMENT: 1. REMOVAL: a. Remove the upper and lower cowlings.
Page 411 Power Plant XL2 Airplane Chapter 71-50 ELECTRICAL HARNESS: Many of the sensor and control functions of the FADEC system are linked to airframe components by an electrical harness called the Low Voltage Harness. This harness is connected to airframe systems and components through two “Cannon plug”...
Page 412 Power Plant XL2 Airplane Chapter 71-60 AIR INTAKES Two openings in the engine cowling, on either side of the propeller, admit air to the engine compartment. Baffles secured to the engine, and sealing against the interior of the cowling, direct the majority of this air past the cylinder cooling fins.
Page 413 Power Plant XL2 Airplane Chapter 71-70 ENGINE DRAINS A small-diameter drain tube exits the intake area of each cylinder head to allow excess (liquid) fuel to drain. The four cylinder drains are combined to form a single engine fuel drain.
Page 414 Engine XL2 Airplane CHAPTER 72 ENGINE P/N 135A-970-006 Chap 72 INITIAL RELEASE - 1 -...
Page 415 Engine XL2 Airplane Chapter 72 Table of Contents Chapter 72 Table of Contents Chapter 72-00 General Chapter 72-10 Front Section Chapter 72-20 Power Section Chapter 72-30 Cylinders Chapter 72-40 Lubrication P/N 135A-970-006 Chap 72 INITIAL RELEASE - 2-...
Page 416 Engine XL2 Airplane Chapter 72 Engine Chapter 72-00 GENERAL: This chapter provides a descriptive overview of the IOF-240-B engine installed on the airplane. Detailed information for routine line maintenance for each engine subsection or system is provided in the appropriate chapter.
Page 417 Engine XL2 Airplane Chapter 72-10 FRONT SECTION: The IOF-240-B engine is direct drive; there is no reduction gear. A front crankshaft seal prevents leakage of engine oil. In the airplane installation, the alternator is installed at the front of the engine and belt-driven via pulleys on the alternator and engine crankshaft.
Page 418 Engine XL2 Airplane Chapter 72-20 POWER SECTION: The engine power section includes the crankshaft, camshaft, connecting rods, valve lifters, and related bearings. The crankshaft rotates on three bearings (front, intermediate, and rear). The bearings are of the metal-to-metal type and are lubricated by oil under pressure fed through drillings in the crankshaft.
Page 419 Engine XL2 Airplane Chapter 72-30 CYLINDER SECTION There are four (identical) cylinder assemblies, each consisting of a steel cylinder barrel with an aluminum alloy cylinder head assembly screwed and shrunk to the barrel. Cooling fins are machined in both the barrel and the head. The interior of the barrel is nitrided for increased wear.
Page 420 Engine XL2 Airplane Chapter 72-40 LUBRICATION: Oil is stored in an oil sump bolted to the bottom of the crankcase near the rear of the engine. A gear-type oil pump at the rear of the engine is driven by the camshaft drive gear.
Page 421 Engine XL2 Airplane P/N 135A-970-006 Chap 72-40 INITIAL RELEASE...
Page 422 Engine Fuel and Control XL2 Airplane CHAPTER 73 ENGINE FUEL AND CONTROL P/N 135A-970-006 Chap 73 INITIAL RELEASE - 1 -...
Page 423 Engine Fuel and Control XL2 Airplane Chapter 73 Table of Contents Chapter 73 Table of Contents Chapter 73-00 General Chapter 73-10 Distribution Fuel Pressure vs. Engine RPM Graph Fuel Filter R&R Chapter 73-20 Fuel Control Troubleshooting Fuel Injector R&R Chapter 73-30 Engine Fuel Indication Fuel Pressure Sensor R&R...
Page 424: Engine Fuel System
Engine Fuel and Control XL2 Airplane Chapter 73 Engine Fuel and Control Chapter 73-00 GENERAL: This chapter provides a descriptive overview of the IOF-240-B engine fuel system as installed on the airplane. Detailed information for routine line maintenance for each engine subsection or system is provided in the appropriate chapter.
Page 425 Engine Fuel and Control XL2 Airplane CHAPTER 73-10 DISTRIBUTION: Fuel from the airframe fuel system is routed to the intake of the engine-driven fuel pump, which is mounted on the front left side of the engine and gear-driven from the camshaft.
Page 426 Engine Fuel and Control XL2 Airplane Fuel entering the engine driven pump passes through a centrifugal separator, where fuel vapor is removed and returned to the airplane fuel tank. Next, it passes into the pump element, where its pressure is increased. Since pump effectiveness varies with engine speed, the pump is designed to produce more pressure and flow than is required by the engine fuel injectors.
Page 427 Engine Fuel and Control XL2 Airplane An adjustable relief valve regulates pump output at lower RPM, while an adjustable internal orifice regulates pressure at high RPM. These adjustments are critical to proper function of the FADEC system. Fuel pressure is displayed on the VM-1000FX Integrated Engine Instrument System, or can be checked by connecting a portable (“laptop”) computer to the...
Page 428 Engine Fuel and Control XL2 Airplane FUEL PRESSURE CHECK AND ADJUSTMENT PROCEDURE: Fuel System Pressure vs. Engine RPM 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Engine (RPM) Check fuel pressure in accordance with TCM manual, OI-22 rev2 chap.
Page 429 Engine Fuel and Control XL2 Airplane FUEL FILTER REMOVAL AND REPLACEMENT: CAUTION: ORIFICES IN FUEL INJECTORS ARE EXTREMELY SMALL AND SUSCEPTIBLE TO CONTAMINATION. AT ANY TIME MAINTENANCE OF ENGINE FUEL SYSTEM IS PERFORMED, TAKE PRECAUTIONS INCLUDING CLEANLINESS OF WORK AREA, CLEAN HANDS, CLEAN SHOP TOWELS, AVAILABILITY OF CLEAN PLUGS FOR FUEL LINE CONNECTIONS, ETC.
Page 430 Engine Fuel and Control XL2 Airplane 1. FUEL FILTER REMOVAL: a. Ensure all electrical switches are off. b. Place cockpit fuel selector in OFF position. c. Place absorbent material under fuel filter. d. Loosen fuel line fittings at inlet and outlet of fuel filter and remove fuel filter.
Page 431 Engine Fuel and Control XL2 Airplane CHAPTER 73-20 FUEL CONTROLLING: Fuel entering the cylinder combustion chambers is metered by the fuel control section of the FADEC. Each fuel injector incorporates an on-off pintle valve which can be electro magnetically actuated by an external coil mounted around the outside of the fuel injector.
Page 432 Engine Fuel and Control XL2 Airplane FUEL INJECTION SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Engine will not start, no fuel No fuel to engine Check tank fuel level, pressure indication confirm fuel selector ON Engine not primed Prime i/a/w AFM/POH...
Page 433 Engine Fuel and Control XL2 Airplane FUEL INJECTOR REMOVAL and REPLACEMENT: 1. FUEL INJECTOR REMOVAL: a. Ensure all electrical switches are off. b. Ensure cockpit fuel selector is off. c. Cut and remove wire ties as necessary to allow fuel injector coil to be lifted off fuel injector.
Page 434 Engine Fuel and Control XL2 Airplane d. Slide injector coil body over injector and orient so that wire lead is away from induction riser. Ensure injector coil is fully seated against shoulder of wrench flat area of fuel injector body.
Page 435 Engine Fuel and Control XL2 Airplane CHAPTER 73-30 ENGINE FUEL INDICATING: Engine fuel pressure indication is measured electronically at the fuel distribution block. In the airplane, fuel pressure indication is derived electronically in the FADEC and sent to the VM1000FX integrated engine instrument display.
Page 436 Engine Fuel and Control XL2 Airplane 2. FUEL PRESSURE SENSOR REPLACEMENT: a. Clean sensor mounting threads as necessary and apply thread sealant (TCM P/N 646940) to second and third threads of sensor. b. Thread sensor into fuel distribution block and torque to 130-150 in/lbs.
Page 437: Ignition
Engine Ignition XL2 Airplane CHAPTER 74 ENGINE IGNITION P/N 135A-970-006 Chap 74 INITIAL RELEASE - 1 -...
Page 438 Engine Ignition XL2 Airplane Chapter 74 Table of Contents Chapter 74 Table of Contents Chapter 74-00 General Chapter 74-10 Electrical Power Supply Chapter 74-20 Distribution Chapter 74-30 Switching Troubleshooting P/N 135A-970-006 Chap 74 INITIAL RELEASE - 2-...
Page 439 Engine Ignition XL2 Airplane Chapter 74 Engine Ignition Chapter 74-00 GENERAL: This chapter provides a descriptive overview of the engine ignition system installed on the airplane. Detailed information for routine line maintenance for each engine subsection or system is provided in the appropriate chapter. More...
Page 440 Engine Ignition XL2 Airplane Chapter 74-10 ELECTRICAL POWER SUPPLY: Unlike conventional magneto ignition systems, the ignition subsystem of the FADEC is not self-powered, but requires an adequate supply of DC power from the airplane electrical system. To provide necessary system redundancy, the FADEC has two power sources.
Page 441 Engine Ignition XL2 Airplane Chapter 74-20 DISTRIBUTION: The FADEC incorporates two Electronic Control Unit (ECU) units, each of which in turn contains two high voltage coil packs and associated circuitry. The unit installed on the right side of the firewall is connected to the top and bottom spark plugs on the rear pair of cylinders (cylinder 1 on the right side of the engine, cylinder 2 on the left side of the engine).
Page 442 Engine Ignition XL2 Airplane Chapter 74-30 SWITCHING: A conventional aircraft ignition switch controls the operation of the ignition portion of the FADEC. Note that this switch is separate from, and independent of, the FADEC A and FADEC B power switches, which control operation of the FADEC system as a whole (both ignition and fuel control functions).
Page 443 Engine Ignition XL2 Airplane IGNITION FAULT ISOLATION TABLE: Complaint Possible Cause Remedy Engine will not start Ignition switch OFF or turn switch ON, check for grounded wires grounded wires Spark plugs fouled, Remove and clean. Gap improperly gapped, or i/a/w spark plug loose manufacturer’s...
Page 444 Engine Ignition XL2 Airplane Rough engine at speeds Loose or improperly Torque to 300-360 in/lbs. above idle gapped spark plugs Adjust to proper gap. High energy leak in inspect, replace lead as ignition harness required FADEC fault Perform FADEC fault Isolation per TCM manual section 12-7.
Page 445 Engine Ignition XL2 Airplane arc where the outer shell of the plug can be grounded, and where the plug electrodes are visible. c. Remove all ignition leads from remaining spark plugs in other cylinders. Ensure lead contact springs are isolated from ground.
Page 446 Air Induction XL2 Airplane CHAPTER 75 AIR INDUCTION P/N 135A-970-006 Chap 75 INITIAL RELEASE - 1 -...
Page 447 Air Induction XL2 Airplane Chapter 75 Table of Contents Chapter 75 Table of Contents Chapter 75-00 General Alternate Air System Functional Check Induction Air Filter Cleaning WOT Throttle Switch Functional Check WOT Throttle Switch Adjustment Troubleshooting P/N 135A-970-006 Chap 75...
Page 448 Air Induction XL2 Airplane Chapter 75 Air Induction Chapter 75-00 GENERAL: This chapter describes provisions for admitting and controlling air to the combustion section of the engine. In normal operation, air at ambient temperature is admitted through an air filter assembly, which incorporates an oil-saturated textile filter element to trap and remove dust and other foreign material.
Page 449 Air Induction XL2 Airplane Next, the air passes through the air throttle body, an aluminum casting which accommodates the movable throttle valve. There is no restriction or venturi in this casting. An idle speed adjustment screw adjacent to the throttle bell-crank arm allows the engine idle speed to be set.
Page 450 Air Induction XL2 Airplane On the opposite side of the throttle body, a microswitch assembly provides the FADEC system with a signal when the throttle is at the wide open position (WOT). This is required on fixed-pitch engine/propeller installations only to signal...
Page 451 Air Induction XL2 Airplane The WOT lamp in the Health Status Annunciator (HSA) illuminates to provide crew confirmation that this function has been activated and that the FADEC will command best power fuel mixture. After passing through the throttle assembly, air enters the cast aluminum induction manifold on top of the engine.
Page 452 Air Induction XL2 Airplane h. Replace induction air filter. CAUTION: PROLONGED ENGINE OPERATION USING UNFILTERED (ALTERNATE) AIR MAY RESULT IN INGESTION OF FOREIGN MATERIAL, SHORTENED ENGINE COMPONENT LIFE, OR ENGINE DAMAGE. USE ALTERNATE AIR ONLY IF PRIMARY (FILTERED) AIR SOURCE IS BLOCKED.
Page 453 Air Induction XL2 Airplane h. Allow filter to air dry at room temperature. i. Spray filter oil, K & N Engineering, Inc., P/N 99-0504, into pleats of filter element from outside making one “pass” of spray can for each pleat of filter.
Page 454 Air Induction XL2 Airplane WOT THROTTLE SWITCH ADJUSTMENT PROCEDURE: Refer to TCM Installation Manual p/n: OI-22 chap. 6 for adjustment procedure. a. Ensure all electrical switches are off. b. Remove upper cowling. c. Remove air filter to allow visual inspection of interior of air throttle assembly.
Page 455: Engine Controls
Engine Controls XL2 Airplane CHAPTER 76 ENGINE CONTROLS P/N 135A-970-006 Chap 76 INITIAL RELEASE - 1 -...
Page 456 Engine Controls XL2 Airplane Chapter 76 Table of Contents Chapter 76 Table of Contents Chapter 76-00 General FADEC System Description FADEC Health Status Annunciator (HSA) Chapter 76-10 Power Control Throttle Cable R&R Throttle Rigging Chapter 76-20 Emergency Shutdown P/N 135A-970-006...
Page 457 Engine Controls XL2 Airplane Chapter 76 Engine Controls Chapter 76-00 GENERAL: This chapter provides a descriptive overview of the control systems for the IOF- 240-B engine installed on the airplane. Detailed information for routine line maintenance for each engine subsection or system is provided in the appropriate chapter.
Page 458 Engine Controls XL2 Airplane FADEC SYSTEM DESCRIPTION AND FUNCTIONAL OVERVIEW: LEGEND FUEL PUMP OUTLET PRESSURE FUEL INLET FROM FUEL PUMP AIRCRAFT SUPPLY RETURN TO AIRCRAFT SUPPLY CONTROL PULSE FROM FADEC MPC 20 MICRON FILTER VARIABLE PULSEWIDTH CONTROLS AMOUNT OF FUEL...
Page 459 Engine Controls XL2 Airplane In the extremely unlikely event of complete failure of an entire ECU (both processors and both high voltage sections), the engine will continue to run at reduced power, as the ECU’s are arranged to control cylinders paired on opposite sides of the engine.
Page 460 Engine Controls XL2 Airplane At the appropriate time before the cylinder reaches top dead center (TDC) on the compression stroke, the spark plugs are fired. Engine timing is established by the FADEC ECU’s and cannot be manually set or verified.
Page 461 Engine Controls XL2 Airplane i. Check alternator load on VM1000FX. j. Press TEST switch on HSA. All bulbs will illuminate. k. Release test switch. l. Turn FADEC PWR A switch OFF. Verify that there is no RPM drop or bump (RPM does not change). AUX PWR lamp will illuminate and BATT LO lamp may illuminate.
Page 462 Engine Controls XL2 Airplane w. Set ignition switch to R position, check RPM and HSA: x. RPM drop minimum: 10 RPM. y. RPM drop maximum: 150 RPM. z. HSA left side channel lamps: ILLUMINATED NOTE: If ignition switch remains in R position for more than 30 seconds, the FADEC warning will illuminate.
Page 463 Engine Controls XL2 Airplane Chapter 76-10 POWER CONTROL The power cable, comprised of a fixed outer sheath and a moving inner element, transmits movement from the cockpit throttle lever to the air throttle unit at the top of the engine. Attachments at both ends secure the outer sheath to the airframe.
Page 464 Engine Controls XL2 Airplane POWER (THROTTLE) CABLE REMOVAL AND REPLACEMENT: 1. Removal: a. Remove belly panel. b. Remove upper and lower engine cowls. c. Remove and discard cotter pin on engine end of throttle cable. d. Loosen castle nut and remove large washer. Note position of all washers.
Page 465 Engine Controls XL2 Airplane l. Loosen and remove WDG clamp aft of firewall from cable. m. Remove and discard cotter pin from throttle lever end of throttle cable. n. Loosen castle nut and remove large washer. Note position of all washers.
Page 466 Engine Controls XL2 Airplane Chapter 76-20: EMERGENCY SHUTDOWN: The normal means of shutting down the airplane engine is by moving the ignition switch to the OFF position. This grounds all four high voltage coils in the MPC units. This method is also the primary means of emergency engine shutdown.
Page 467: Engine Indicating
Engine Indicating XL2 Airplane CHAPTER 77 ENGINE INDICATING P/N 135A-970-006 Chap 77 INITIAL RELEASE - 1 -...
Page 468 Engine Indicating XL2 Airplane Chapter 77 Table of Contents Chapter 77 Table of Contents Chapter 77-00 General VM1000FX Panel DPU R&R Display Panel R&R HSA R&R Non-FADEC Sensor R&R Troubleshooting P/N 135A-970-006 Chap 77 INITIAL RELEASE - 2-...
Page 469 Engine Indicating XL2 Airplane Chapter 77 Engine Indicating Chapter 77-00 GENERAL: The airplane uses a Vision Micro Systems VM1000FX integrated engine instrument display system for all engine and systems monitoring information. The system consists of a Display Processing Unit (DPU) mounted behind the...
Page 470: Exhaust
Engine Indicating XL2 Airplane Following is an overview of information displayed on the VM1000FX panel and its source: Information displayed Information source Sensor location Manifold pressure FADEC intake manifold (2) FADEC SSA (speed sensor assembly) on crankcase Oil Pressure oil pressure sensor...
Page 471 Engine Indicating XL2 Airplane b. Disconnect the ribbon cable (connecting the DPU to the display panel) and the two multi-pin connectors (connecting the DPU to airplane electrical power and sensors). c. Remove screws securing DPU; remove DPU. 2. DPU REPLACEMENT: a.
Page 472 Engine Indicating XL2 Airplane d. Replace instrument panel and secure screws retaining panel. e. Apply power to airplane electrical system and perform functional check of integrated engine instrument system. CAUTION: TO CLEAN FACE OF DISPLAY PANEL, ONLY USE A SOFT CLOTH DAMPENED WITH CLEAR WATER, OR BREATHE ON PANEL TO “FOG”...
Page 473 Engine Indicating XL2 Airplane 2. REPLACEMENT: a. Ensure all electrical switches are off. b. Reinstall affected sensor. c. Reconnect sensor. d. Apply power to airplane electrical system and perform functional check of integrated engine instrument system. NOTE: All non-FADEC sensors (oil pressure, oil temperature, volts, and amps) are connected to the integrated engine instrument system via multi-pin connector VM-01 on the DPU.
Page 474 Engine Indicating XL2 Airplane INTEGRATED ENGINE INSTRUMENT TROUBLESHOOTING TABLE: Complaint Possible cause Remedy VM1000FX completely defective power circuit replace inoperative (panel remains breakers (2) blank) defective power wiring replace defective DPU replace DPU defective display panel replace display panel defective ribbon cable from...
Page 475 Engine Exhaust XL2 Airplane CHAPTER 78 ENGINE EXHAUST P/N 135A-970-006 Chap 78 INITIAL RELEASE - 1 -...
Page 476 Engine Exhaust XL2 Airplane Chapter 78 Table of Contents Chapter 78 Table of Contents Chapter 78-00 General Chapter 78-10 Collector/Nozzle Muffler R&R Exhaust Pipe R&R Troubleshooting P/N 135A-970-006 Chap 78 INITIAL RELEASE - 2-...
Page 477 Engine Exhaust XL2 Airplane Chapter 78 Engine Exhaust Chapter 78-00 GENERAL: The exhaust system installed on the airplane’s TCM IOF-240-B engine includes individual exhaust pipes from each cylinder and a single muffler located below the engine. A single overhead discharge pipe extends through the right side of the lower cowling.
Page 478 Engine Exhaust XL2 Airplane Chapter 78-10 COLLECTOR / NOZZLE: Individual exhaust pipes are secured to the exhaust port by brass exhaust nuts screwed onto the cylinder exhaust studs. CAUTION: EXHAUST NUTS ARE INTENDED FOR ONE-TIME USE ONLY. RE-USE OF EXHAUST NUTS COULD RESULT IN INFLIGHT LOOSENING OF EXHAUST CONNECTIONS AND POSSIBLE INFLIGHT FIRE.
Page 479 Engine Exhaust XL2 Airplane 2. MUFFLER REPLACEMENT: a. Reverse above steps. INDIVIDUAL EXHAUST PIPE REMOVAL AND REPLACEMENT: 1. EXHAUST PIPE REMOVAL: a. Remove upper and lower cowling. b. Disconnect clamp at junction of exhaust pipe and muffler. c. Cut wire ties as required to provide sufficient slack to remove EGT probe from exhaust pipe.
Page 480 Engine Exhaust XL2 Airplane e. Tighten clamp at exhaust pipe / muffler junction. f. Apply small amount of high temperature anti-seize compound to second and third threads of EGT probe compression fitting. g. Carefully insert EGT probe into compression fitting. Thread on B-nut and torque to 70 +/- 5 in/lbs.
Page 481 Engine Oil XL2 Airplane CHAPTER 79 ENGINE OIL P/N 135A-970-006 Chap 79 INITIAL RELEASE - 1 -...
Page 482 Engine Oil XL2 Airplane Chapter 79 Table of Contents Chapter 79 Table of Contents Chapter 79-00 General Chapter 79-10 Storage Chapter 79-20 Distribution Oil Cooler/Hose R&R Oil Filter Element R&R Oil Draining Chapter 79-30 Indicating Oil Temperature Sensor R&R Oil Temperature Sensor...
Page 483 Engine Oil XL2 Airplane Chapter 79 Engine Oil Chapter 79-00 GENERAL: This chapter describes only those components of the engine oil system that are external to the engine. For internal components, refer to the “lubrication” subchapter of the engine chapter.
Page 484 Engine Oil XL2 Airplane Chapter 79-10 STORAGE: The IOF-240-B’s oil supply is stored in a welded steel oil sump secured to the bottom of the crankcase. Capacity of the sump is 6.0 US quarts. An oil filler tube is secured to the (airplane’s) right side of the sump and extends upward.
Page 485 Engine Oil XL2 Airplane Chapter 79-20 DISTRIBUTION: Components of the oil system external to the engine include a full flow oil filter and oil cooler. The full flow oil filter element is attached directly to the oil filter adapter at the lower right rear of the engine accessory gear-case.
Page 486 Engine Oil XL2 Airplane The oil cooler is mounted on the left side of the firewall and connected to the oil cooler adapter by supply and return hoses. An air duct directs air from the low- temperature / high pressure portion of the cowling (above the engine cooling baffles) downward to the oil cooler.
Page 487 Engine Oil XL2 Airplane b. Remove upper and lower cowling. c. Position container and/or absorbent material below oil filter element to accommodate unavoidable minor spillage. d. Using filter wrench, remove oil filter. NOTE: It is recommended that filter element be opened (use oil filter cutter tool) and entire element be examined for metal or other foreign material.
Page 488 Engine Oil XL2 Airplane Chapter 79-30 INDICATING: An electronic oil temperature sensor is threaded into the oil cooler adapter. Information from this sensor is displayed on the VM1000FX Integrated Engine Instrument Display System An electronic oil pressure sensor is mounted on the firewall and plumbed to the oil pressure port on the oil cooler adapter.
Page 489: Starting
Starting XL2 Airplane CHAPTER 80 STARTING P/N 135A-970-006 Chap 80 INITIAL RELEASE - 1 -...
Page 490 Starting XL2 Airplane Chapter 80 Table of Contents Chapter 80 Table of Contents Chapter 80-00 General Chapter 80-10 Cranking Starter R&R Troubleshooting P/N 135A-970-006 Chap 80 INITIAL RELEASE - 2-...
Page 491 Starting XL2 Airplane Chapter 80 Starting Chapter 80-00 GENERAL: The IOF-240-B engine installed on the airplane is equipped with a lightweight electric starter. The starter is installed on the accessory case at the top center of the rear of the engine and drives the crankshaft directly through internal gears.
Page 492 Starting XL2 Airplane SECTION 80-10 CRANKING: The starter solenoid is energized by DC power from the spring-loaded “start” position of the ignition/starter key switch. This circuit is powered by a 2-amp circuit breaker on the main distribution bus. Primary power is provided by a heavy-gauge cable from the battery contactor in the aft fuselage.
Page 493 Starting XL2 Airplane 1. STARTER REMOVAL: a. Ensure all electrical switches are off. b. Remove aft baggage compartment closeout and disconnect NEGATIVE cable from airplane primary battery. c. Remove upper engine cowling. d. Disconnect heavy electrical cable from power stud on starter.
Page 494 Starting XL2 Airplane h. Reconnect negative battery cable; reinstall aft baggage compartment closeout. i. Perform functional test. STARTER SYSTEM TROUBLESHOOTING TABLE: Complaint Possible Cause Remedy Starter inoperative defective “START” circuit replace (“STARTER ENGAGED” breaker does not illuminate) defective ignition/start replace...
Page 495: Wiring Diagrams
Wiring Diagrams XL2 Airplane CHAPTER 91 WIRING DIAGRAMS P/N 135A-970-006 Chap 91 INITIAL RELEASE - 1 -...
Page 496 Wiring Diagrams XL2 Airplane Chapter 91 Table of Contents Chapter 91 Electrical Block Diagram Drawing Number Title Revision 135A-81-010 Power Generation/ Distribution 135A-81-011 Starting System 135A-81-012 Fuel System 135A-81-013 FADEC System Cabin Harness 135A-81-014 VM1000FX 135A-81-015 Annunciation 135A-81-016 Flap System...
Page 497 Wiring Diagrams XL2 Airplane LIBERTY XL-2 ELECTRICAL BLOCK DIAGRAM ENGINE ALTER- NATOR STARTER RELAY FADEC VOLTAGE START CONTROL SWITCH ELECTRICAL REGULATOR SYSTEM FADEC FADEC BACKUP BACKUP PRIMARY MAIN BATTERY ELECTRICAL ELECTRICAL BATTERY AVIONICS SWITCH MASTER SWITCH MAIN AVIONICS AVIONICS RELAY...

Liberty XL2 Maintenance Manual

Maintenance Manual

Chapter 05 Time Limits/Maintenance Checks/Inspection Intervals

Chapter 12 Servicing

Chapter 34 Navigation and Pitot/Static

Chapter 51 Standard Practices - Structures

Quick Links

Chapters

Need help?

Questions and answers

Related Manuals for Liberty XL2

Summary of Contents for Liberty XL2

Table of Contents