Liberty XL-2 Maintenance Manual

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100 Aerospace Drive, Melbourne, FL 32901

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Liberty

Technical

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Document Number: 135A-970-100

Revision: E

Liberty XL-2 Airplane

Maintenance Manual

TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING

PHOTOCOPYING, RECORDING OR USE OF ANY INFORMATION STORAGE AND RETRIEVAL SYSTEM

WITHOUT EXPRESS WRITTEN PERMISSION OF LIBERTY AEROSPACE INC.

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Summary of Contents for Liberty XL-2

Page 1 PROPRIETARY. ALL RIGHTS RESERVED. NO PORTION OF THIS DOCUMENT MAY BE REPRODUCED OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING, RECORDING OR USE OF ANY INFORMATION STORAGE AND RETRIEVAL SYSTEM WITHOUT EXPRESS WRITTEN PERMISSION OF LIBERTY AEROSPACE INC.
Page 2 PREFACE XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Preface P/N 135A-970-100 Page ii REVISION E...
Page 3 Installation of parts deviating from Liberty Aerospace approved type-design criteria is not allowed. Liberty Aerospace accepts no liability for the suitability, durability, longevity, or safety of such parts installed on the XL-2 aircraft. Installation of parts deviating from type design must be performed using Instructions for Continued Airworthiness prepared by the part manufacturer and approved by the FAA for the subject installation.
Page 4: Table Of Contents
PREFACE XL-2 AIRPLANE Table of Contents REFACE ABLE OF ONTENTS UPERSEDE OTICE IST OF FFECTIVE AGES IGHLIGHT OF EVISIONS ECORD OF EVISION IST OF ERVICE ULLETINS ERVICE ULLETINS ELEASED FTER UBLICATION XIII ABLE OF HAPTERS Preface P/N 135A-970-100 Page iv...
Page 5: Preface
PREFACE XL-2 AIRPLANE Supersede Notice This manual supersedes and renders obsolete Liberty Aerospace Maintenance Manual 135A-970-006 revision A dated October 2008. List of Effective Pages Use this page(s) to determine current revision and effective date for each page in the Maintenance Manual. As revisions are issued this list of effective pages will be amended.
Page 6 PREFACE XL-2 AIRPLANE PAGE REVISION DATE PAGE REVISION DATE 28-01 thru 28-02 07/14/11 70-01 thru 70-06 07/31/09 28-03 thru 28-17 01/30/10 71-01 thru 71-02 07/14/11 28-17 thru 28-36 07/14/11 71-03 thru 71-64 07/31/09 28-37 thru 28-56 07/31/09 71-65 thru 71-76...
Page 7: Highlight Of Revisions
PREFACE XL-2 AIRPLANE Highlight of Revisions Revision Revision Chapter Description Date 07/31/2009 Initial release of the entire manual 135A-970-100. 10/28/2009 Incorporated approved firewall blanket life extension. 01/30/2010 Updated the chart to indicate the inclusion of SID-09- 001. Stepped through all chapters and matched the table on page x of the Preface (Chapter 00).
Page 8 PREFACE XL-2 AIRPLANE Revision Revision Chapter Description Date 06/21/2010 Updated the List of effected Pages to include new chapter 30. Added Life Limits for Fire Extinguisher. Re-formatted the tables for readability . Added inspection points for fire extinguisher. Added inspection points for bolts associated with the stabilizer.
Page 9 PREFACE XL-2 AIRPLANE Revision Revision Chapter Description Date Correctly point to the battery limits for the ELT batteries to Chapter 05 (was Chapter 04). Updated the procedures to torque castellated nuts. Added procedures to the section for the yoke control to remove and install the push-to-talk switch/button.
Page 10: Record Of Revisionx
PREFACE XL-2 AIRPLANE Record of Revision Use this checklist to record and control of all of the revisions you put in this Airplane Maintenance Manual (AMM). Put the affected pages of the revision into the AMM as soon as you get them. Remove and destroy the pages which are superseded.
Page 11: List Of Service Bulletins
Liberty Aerospace Maintenance Manual 135A-970-100 and are listed in the chart below. Information relevant to the XL-2 model aircraft from these service documents has been incorporated in this manual. The full content of all Liberty Aerospace service documents is available on www.libertyaircraft.com...
Page 12 Landing Gear Chapter 32 SIL-07-002 REV C Mt propeller installation Propeller Chapter 61 Increase life limit of the Airworthiness SIL-06-008 Liberty XL-2 from 3,333 Chapter 04 Limitations hours to 5,000 hours. Cabin Heat and Defog Environmental SIL-06-007 Chapter 21 System...
Page 13: Service Bulletins Released After Publication
Service Bulletins Released After Publication Liberty Aerospace strives to provide clear, concise, and accurate information and instructions based on the best available engineering data at the time of publication. Ongoing process improvements at Liberty may change specification or procedure after manual release.
Page 14 PREFACE XL-2 AIRPLANE Service Documents Published After this Manual Affected Service Bulletin Subject Section Title Chapter Preface P/N 135A-970-100 Page xiv REVISION E...
Page 15: Table Of Chapters
PREFACE XL-2 AIRPLANE Table of Chapters Chapters Description Page Introduction 01-01 General Description 03-01 Airworthiness Limitations 04-01 Time Limits/Maintenance Checks/Inspection Intervals 05-01 Dimensions and Areas 06-01 Lifting and Jacking 07-01 Leveling and Weighing 08-01 Towing and Taxiing 09-01 Parking and Mooring...
Page 16 PREFACE XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Preface P/N 135A-970-100 Page xvi REVISION E...
Page 17 INTRODUCTION XL-2 AIRPLANE CHAPTER 01 INTRODUCTION Chapter 01 P/N 135A-970-100 REVISION E Page 1 of 20...
Page 18 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 19 INTRODUCTION XL-2 AIRPLANE Table of Contents 01-00 ECTION ENERAL 00-01 ECTION AINTENANCE ANUAL TYLE 01-10 ECTION EVISION SYSTEMS 10-01 ECTION EFORMATTED HAPTERS EVISION RACKING 01-20 ECTION UBLICATIONS 20-01 ECTION ERVICE OCUMENTS 20-02 ECTION ELATED UBLICATIONS 01-30 ECTION HAPTER ORMAT AND...
Page 20 INTRODUCTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 01 P/N 135A-970-100 Page 4 of 20 REVISION E...
Page 21 XL-2 AIRPLANE Section 01-00 General Liberty Aerospace, Inc. is releasing this manual as a brand new manual. The purpose of the Maintenance Manual is to furnish maintenance personnel with all data required for normal maintenance of the Liberty XL-2 airplane. It comprises detailed system and subsystem descriptions, troubleshooting tables, component removal, installation procedures, and detailed maintenance procedures.
Page 22 INTRODUCTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 01-00 P/N 135A-970-100 Page 6 of 20 REVISION ~...
Page 23 INTRODUCTION XL-2 AIRPLANE Section 01-10 Revision systems This section details the methods used to track revisions and changes to the chapters in this manual. In the initial release of the manual and the chapters, revisions were tracked in the front matter sections of the manual. With the changes to the format of this manual, the tracking of changes and revisions moved to the end of the front matter behind the Table of Contents and Table of Chapters.
Page 24 INTRODUCTION XL-2 AIRPLANE PAGE LEFT INTENTIONAL BLANK 01-10 P/N 135A-970-100 Page 8 of 20 REVISION E...
Page 25 This section describes the different documents that are published. Service Documents Section 20-01 Liberty Aerospace, Inc. has adopted a service document format which will provide the user with an explanation of the compliance criticality of the document. This format was developed by the General Aviation Manufacturers Association (GAMA) to standardize service documents used by aviation manufacturers.
Page 26 Liberty Aerospace will distribute SSI notification directly to the owners of the affected aircrafts. SSI's will not be included in the general service bulletin set but will be made available through Liberty Customer Service to owners of the affected aircrafts only. An SSI may contain updates to the Instructions for Continued Airworthiness applicable only to the listed aircrafts.
Page 27 INTRODUCTION XL-2 AIRPLANE Internet Order Supplied From Available Publication Publication Name With Liberty Liberty From Number Aircraft Aircraft Aircraft Manufacturer web site Inc. IOF-240-B Maintenance M-22 Manual Accessory Documents GARMIN GNS 430 User Guide 190-00140-00 GNS 430 Installation Manual 190-00140-05...
Page 28 INTRODUCTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 01-20 P/N 135A-970-100 Page 12 of 20 REVISION ~...
Page 29 INTRODUCTION XL-2 AIRPLANE Section 01-30 Chapter Format and Layout Along with the changes to the style of the chapters, there were changes to the format and layout of pages. This section describes the different changes to Changed Text, Blank Pages, Notes, Cautions, and Warnings Callouts, Section Headings and Section Text, Headers and Footers, Figure and Table Captions, and Procedures.
Page 30 This change allows the document to be more scanning friendly to the reader. The headers contain the logo for Liberty Aerospace, Inc. along the inside edge of each page. The outside edge identifies the chapter by title (for example INTRODUCTION) and the subject airplane (for example XL-2 Airplane).
Page 31 INTRODUCTION XL-2 AIRPLANE Figure 01-1 Examples of the Maintenance Manual Footer Procedures Section 30-07 Procedures will have an unnumbered heading that is in the center on the page. Each procedure will begin on a new page to distinguish it from a preceding procedure.
Page 32 INTRODUCTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 01-30 P/N 135A-970-100 Page 16 of 20 REVISION E...
Page 33 INTRODUCTION XL-2 AIRPLANE Section 01-40 Manual Arrangements The overall arrangement of this Maintenance Manual is in accordance with the Air Transport Association of America (ATA) Specification number 100. In addition, the manual complies with the General Aviation Manufacturers Association (GAMA) Specification number 2 issue in January 1978 - Specification for Manufacturers Maintenance Data.
Page 34 INTRODUCTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 01-40 P/N 135A-970-100 Page 18 of 20 REVISION E...
Page 35 INTRODUCTION XL-2 AIRPLANE Section 01-50 Main Chapter Groups The maintenance manual combines the chapters in to five groups. This grouping brings together chapters that cover similar information about the airplane. Shown in Table 01-2 are the five groups, and the chapters that are in that group.
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Page 37 GENERAL DESCRIPTION XL-2 AIRPLANE CHAPTER 03 GENERAL DESCRIPTION Chapter 03 P/N 135A-970-100 REVISION E Page 1 of 16...
Page 38 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 39 GENERAL DESCRIPTION XL-2 AIRPLANE Table of Contents 03-00 ECTION ENERAL 00-01 ECTION ESCRIPTION 03-01 ECTION ENDER OCUMENTATION 03-02 ECTION IRCRAFT EASUREMENTS 02-01 ECTION EFERENCE LANES 02-02 ECTION EASUREMENTS FROM THE 02-03 ECTION EASUREMENTS FROM THE ATERLINE AND TATION 03-03 ECTION...
Page 40 GENERAL DESCRIPTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 03 P/N 135A-970-100 Page 4 of 16 REVISION E...
Page 41 Melbourne, Florida, USA, 32901 Phone: 321-752-0332 Section 00-01 Description The Liberty XL-2 airplane is a low-wing two-place aircraft with tricycle landing gear. Its central structural element is a welded steel tubing frame or “chassis” which has the following components attached: •...
Page 42 GENERAL DESCRIPTION XL-2 AIRPLANE Fuel for the engine is from a single 28-gallon (106-liter) usable capacity aluminum tank. The tank is installed in the fuselage between the pilot/passenger seatbacks and the baggage compartment. The preferred propeller is the MT Propeller, which...
Page 43 GENERAL DESCRIPTION XL-2 AIRPLANE Section 03-01 Vender Documentation This manual may refer to the following vendors, and their documentation. IOF-240 B Teledyne Continental Motors 2039 Broad Street, Bldg. # 96 Engine Mobile, AL. 36601 Tel: 251-438-8291 Fax: 251-432-7352 Website#: http://www.tcmlink.com...
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Page 45 GENERAL DESCRIPTION XL-2 AIRPLANE Section 03-02 Aircraft Measurements This section contains the measurements of the Liberty XL2 airplane. Section 02-01 Reference Planes As a standard, the measurements are from three reference planes. These planes are the Waterline, Station, and the Butt Line, also known as the centerline. Figure 03-1 shows the location of the three planes.
Page 46 GENERAL DESCRIPTION XL-2 AIRPLANE Figure 03-2 Waterline and Station Reference Points Section 02-02 Measurements from the Butt Line Measurements from the Butt Line are measurements port or starboard from the center of the airplane. See Figure 03-3 for various measurements that are left and or right of the butt line.
Page 47 GENERAL DESCRIPTION XL-2 AIRPLANE Section 02-03 Measurements from the Waterline and Station Measurements for Waterline and Station are from an imaginary plane below the landing gear and forward of the propeller. That is the reason that on the airplane there are points defined as the Waterline and Station reference points. See Section 02-01 Reference Planes in this chapter.
Page 48 GENERAL DESCRIPTION XL-2 AIRPLANE PAGE LEFT INTENTIONAL BLANK 03-02 P/N 135A-970-100 Page 12 of 16 REVISION E...
Page 49 GENERAL DESCRIPTION XL-2 AIRPLANE Section 03-03 Aircraft Access Panels and Cowlings This section describes the type and location of the various cowlings, panels and access panels on the exterior and interior of the airplane. Figure 03-5, Figure 03-6, Figure 03-7, and Figure 03-8 show the detail of the location of the access panels.
Page 50 GENERAL DESCRIPTION XL-2 AIRPLANE Figure 03-6 Access Panels Starboard Figure 03-7 Wing Root and Engine Oil Filler Access Panel 03-03 P/N 135A-970-100 Page 14 of 16 REVISION E...
Page 51 GENERAL DESCRIPTION XL-2 AIRPLANE Figure 03-8 Interior Access Panels Aft of the Cockpit 03-03 P/N 135A-970-100 REVISION E Page 15 of 16...
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Page 53 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE CHAPTER 04 AIRWORTHINESS LIMITATIONS Chapter 04 P/N 135A-970-100 REVISION D Page 1 of 22...
Page 54 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 55 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Table of Contents 04-00 ECTION ENERAL 04-01 ECTION IRWORTHINESS IMITATIONS 04-02 ECTION IMITS AND ANDATORY NSPECTIONS 02-01 ECTION TEMS UBJECT TO IMITS 02-02 ECTION TEMS UBJECT TO ANDATORY NSPECTIONS 02-03 ECTION ONDED OMPOSITE AMINATES 02-04 XL-2 C...
Page 56 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 04 P/N 135A-970-100 Page 4 of 22 REVISION ~...
Page 57 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Section 04-00 General The Airworthiness Limitations section contains the following requirements: Life Limits and Mandatory Inspections: • Structure and Components Subject to Life Limits • Mandatory Inspections • Battery Replacement Requirements • External Surface Paint Requirements...
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Page 59 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Section 04-01 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.
Page 60 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE DATE APPROVED 02/16/2011 For: Melvin D Taylor, Manager Atlanta Aircraft Certification Office Federal Aviation Administration Central Region Table 04-1 FAA Approvals 04-01 P/N 135A-970-100 Page 8 of 22 REVISION D...
Page 61 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Section 04-02 Life Limits and Mandatory Inspections This section details items that are subject to life limits and mandatory inspections. Items Subject to Life Limits Section 02-01 The items listed in Table 04-2 are life-limited items with mandatory replacement times.
Page 62 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Items Subject to Mandatory Inspections Section 02-02 Table 04-3 details those components that are subject to mandatory inspection. Component Inspection Type Inspection Interval Refer to Chapter 05 Annual for all aircraft Throttle Control 135A-50-017 and 100 hour as...
Page 63 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Component Inspection Type Inspection Interval For airplanes Inspect every 25 hours equipped with a Time-In-Service or Refer to Chapter 05 standard exhaust Dawley every 12 months, system and the Drawing Engine (Firewall Forward) whichever occurs first,...
Page 64 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Component Inspection Type Inspection Interval Refer to Chapter 05 Annual for all aircraft Tail Plane 135A-30-615 and 100 hour as Control Surfaces Inspection Attachment Lug applicable per Part 91 Checklist Refer to Chapter 05 Annual for all aircraft...
Page 65 Solid, or Sandwich. Different thicknesses of laminates are used to form a structural support to distribute stresses through the structure. The majority of the Liberty XL-2 fuselage is sandwich construction. There are areas of the structure like the “rollover” hoop structure that are solid laminate. Bond lines are areas of solid laminates joined together with a permanent two-part epoxy paste adhesive.
Page 66 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Figure Description Bond Joint Callout Horizontal Center Line between Upper and Lower Fuselage Lap Joint Bulkhead Baggage Bay between Upper and Lower Fuselage Flange Joint Bulkhead Mid Fuselage and the Upper and Lower Fuselage Flange Joint...
Page 67 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE During inspections, give attention to joints between the fuselage and baggage bay floor supports (item number 12 in Figure 04-5); which can be viewed through the floor access panel. There are two baggage bay floor supports (Port and Starboard), which are bonded to the fuselage.
Page 68 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Figure Description Bond Joint Callout Battery Braces (Main and Backup) and Lower Fuselage Face-to-Face Joint Bond Line between Hoop Reinforcement and Upper & Face-to-Face Joint Lower Fuselage Ducts NACA Cabin Air (Port and STBD) and Lower...
Page 69 Table 04-7 and Figure 04-7 through Figure 04-9 details the location of the various stiffeners and bond lines for compliance for the gross weight of 1750 lbs. upgrade. LIBERTY XL-2 COMPLIANCE AT A GROSS WEIGHT OF 1750LBS • For SN0007 and SN0009 thru SN0115 if modified in accordance with RKI-SIL-08-001 for a maximum gross weight of 1750 lbs.
Page 70 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Figure 04-8 FWD Bulkhead and Lower Fuselage Bond Lines Figure 04-9 Seat Back Stiffener and Lower Fuselage Bond Lines 04-02 P/N 135A-970-100 Page 18 of 22 REVISION D...
Page 71 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Battery Inspection and Replacement Section 02-05 Requirements Inspect, and replace as required, the batteries listed in this table with new batteries at the intervals shown or at the recommended interval by the battery’s vendor or at the interval prescribed by applicable local regulations, which ever occurs first.
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Page 73 AIRWORTHINESS LIMITATIONS XL-2 AIRPLANE Section 04-03 External Surface Paint Requirements To ensure 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, Figure 04-10 defines the zones.
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Page 75 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE CHAPTER 05 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS CHAPTER 05 P/N 135A-970-100 REVISION D Page 1 of 52...
Page 76 XL-2 AIRPLANE Copyright © 2010 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 77 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Table of Contents 05-00 ECTION ENERAL 05-10 ECTION ETWEEN VERHAUL IMITS 05-20 ECTION CHEDULED AINTENANCE HECKS NSPECTION HECKLIST NGINE PERATIONAL HECKLIST NGINE IREWALL ORWARD HECKLIST ROPELLER NSPECTION HECKLIST ABIN NSPECTION HECKLIST VIONICS NSPECTION HECKLIST...
Page 78 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK CHAPTER 05 P/N 135A-970-100 Page 4 of 52 REVISION D...
Page 79 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Section 05-00 General Maintenance personnel should refer to Chapters 04 and 05 as guidelines for proper scheduling and execution of inspections and maintenance. Inspections and intervals described in these two chapters are considered the minimum required to maintain airplane in airworthy condition.
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Page 81 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Section 05-10 Time Between Overhaul Limits Table 05-1 shows the time between overhauls for various components. Component Specified Time Between Overhaul Engine, Teledyne • 2000 operating hours or 12 years, IOF-240B Including Continental whichever occurs first...
Page 82 The TCM part number provides a Power-Sonic Corporation model PS-12120 12vdc 12 Ah battery. All batteries installed must have the same expiration date. The Liberty XL-2 will be fitted with either an Ameri-King model AK-450 or Artex model ME406 ELT. Refer to airplane equipment list for model installed.
Page 83 Regulations. Where applicable, additional maintenance intervals are identified and noted next to the affected maintenance item. Annual inspections are required for any Liberty XL-2 airplane that is flown less than 100-hours during any 12 calendar-month period. Do a 100-hour inspection to meet the requirements of an annual inspection.
Page 84 Check Logs for Discrepancies Wash Airplane (such that visibility of imperfections are apparent) Complied with ALL requirements above Table 05-2 Pre-Inspection Checklist Liberty Service Documents are available at the Liberty Aerospace, Inc. website http://www.libertyaircraft.com 05-20 P/N 135A-970-100 Page 10 of 52 REVISION D...
Page 85 RPM) Check for RPM drop when ALT AIR control is pulled. Perform alternator, alternator belt and alternator control unit operation and inspection in accordance with Liberty Maintenance Manual Chapter 24 – Electrical Power Complied with ALL requirements above Table 05-3...
Page 86 Remove upper and lower cowling, check the cowling for cracks, overheated areas, deformation, delaminating, loose or missing fasteners, chafing or abnormal condition and oil, reference Liberty Maintenance Manual Chapter 71 – Power Plant. Inspect engine baffles for cracks and signs...
Page 87 Perform all engine inspections, and maintenance in accordance with TCM IOF- 240-B Maintenance Manual, M-22 Chapter 7, and other manuals as maybe applicable. Check brake fluid level reference Liberty Maintenance Manual Chapter 12 - Servicing. Check engine frame rubber mounts for “sag”.
Page 88 Hours brackets, clamps, and hardware. Visually inspect exhaust system components for evidence of exhaust leakage, reference Liberty Maintenance Manual Chapter 78 – Engine Exhaust. All airplanes with standard reinforced exhaust with the SCAT bypass tube installed (Dawley Drawing 200201-002 or 200201-006 standard and Dawley Drawing 200201-003 or 200201-005 quiet).
Page 89 Check that a split pin is installed properly with no excessive wear. Check large flat washer between bearing rod end and castellated nut is installed; reference Liberty Maintenance Manual Chapter 76- Engine Controls for installation and adjustment procedures. Visually inspect nut-exhaust manifold flange (size .31-24) and verify torque value...
Page 90 Install Check propeller, hub, and blades for damage, abrasions, or other abnormalities in accordance with the MT-Propeller or Sensenich Maintenance Manuals. Reinstall spinner, reference Liberty Maintenance Manual Chapter 61- Propeller. Correct all PROPELLER discrepancies noted. Table 05-5 Propeller Inspection Checklist...
Page 91 Other Initials Confirm all required instrument, control knob and handle markings, and interior and exterior placards are properly displayed and correct, see Liberty Maintenance Manual Chapter 11 – Placards and Markings Check door locking mechanisms for proper “over center” operation;...
Page 92 If the rudder movement is beyond rigging values, it is excessive wear, contact the factory. Reference Liberty Maintenance Manual Chapter 27 – Flight Controls If installed, check the operation of the left and right finger brake; reference Liberty Maintenance Manual Chapter 32 –...
Page 93 100 Hr Annual Other Initials Audio Panel Perform operation check in accordance with Liberty Maintenance Manual Chapter 23 - Communications for audio panel model installed. COM/NAV Receiver #1 Perform operation check in accordance with Liberty Maintenance Manual Chapter 23 - Communications for receiver model installed in the COM1 avionics panel position.
Page 94 CFR 91.413 and 91.217 requirements for the model altitude encoder model installed. Emergency Locator Transmitter Perform operation check and inspection in accordance with Liberty Maintenance Manual Chapter 25 – Equipment and Furnishings for ELT model installed. Correct all AVIONICS discrepancies noted.
Page 95 Check flight control hinges and linkage for excessive wear. If the pin is visible between the teeth of the hinge, it is excessive wear. Refer to Liberty Maintenance Manual Chapter 27 – Flight Controls for details on inspection criteria. Inspect control throttle linkage...
Page 96 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Space Frame and AFT Fuselage Area (AFT Firewall)Inspection Checklist Inspection Interval Item # Item Description 50 Hr 100 Hr Annual Other Initials Check fuel lines in space frame assembly (chassis) for leakage, reference Liberty Maintenance Manual Chapter 28 –...
Page 97 There is to be no evidence of rivets working loose (exhibited by a black ring around the outside edge of any one rivet, also known as a smoking rivet).See Liberty Maintenance Manual Chapter 57 – Wings. Check all exposed areas of the wing...
Page 98 Determine free-play by measuring the internal bore of the lugs and the external diameter of the pins. Report any differences greater than 0.005in to Liberty Customer Service. In addition, moving the wing fore and aft carefully at the wing tip may highlight any free-play.
Page 99 Inspect the wing root fairing and wing ® skin attachment for any Epibond voids or any cracks, reference Liberty Maintenance Manual Chapter 57 – Wings. Install wings; reference Liberty Maintenance Manual Chapter 57 –...
Page 100 Flight Controls. Remove horizontal stabilizers; inspect anti-servo/trim tab drive plates and links, and attachments reference Liberty Maintenance Manual Chapter 27– Flight Controls. Inspect the attachment bolts for the correct size, type, length, and torque. The bolts must be an AN3-7 – 10-32 X 29/32 inch bolt.
Page 101 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE ANDING NSPECTION HECKLIST Table 05-10 details the items to check during the landing gear check. Landing Gear Inspection Checklist Inspection Interval Item # Item Description 50 Hr 100 Hr Annual Other Initials Check tires for condition, wear, proper inflation (50 psi -0/+2 psi).
Page 102 0.240 inches. Check brake linings for condition and wear, reference Liberty Maintenance Manual Chapter 32 – Landing Gear. Check brake caliper for condition, leaks, reference Liberty Maintenance Manual Chapter 32 –...
Page 103 Annual Other Initials Remove cabin heat shroud and inspect muffler for corrosion, holes, and cracks, reference Liberty Maintenance Manual Chapter 21 – Environmental Systems. Check fit of cabin heat shroud around muffler and tail pipe; no air gaps larger than .02” permissible, reference Liberty Maintenance Manual Chapter 21 –...
Page 104 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Cabin Heat Inspection Checklist Inspection Interval Item # Item Description 50 Hr 100 Hr Annual Other Initials Inspect fiberglass instrument panel around both louvers for damage due to heating cycles; reference Liberty Maintenance Manual Chapter 21 –...
Page 105 Chapter 24 – Electrical Power to check primary battery for cleanliness, corrosion of connections, security of mounting and state of charge in accordance with Liberty Maintenance Manual Chapter 24 – Electrical Power Inspect primary battery tray and battery cable terminals for cracks, corrosion or signs of fatigue.
Page 106 Reference Liberty Maintenance Manual Chapter 25 – Equipment and Furnishings Inspect ELT remote switch battery and battery compartment for the following in accordance with Liberty Maintenance Manual Chapter 25 – Equipment and Furnishings: • After use in an emergency •...
Page 107 Re-install engine cowlings. Re-install wheel fairing, if applicable. Perform “Liberty XL-2 Post Inspection Check Flight” using the Liberty XL-2 Post Inspection Check Flight form confirming all items on the form have been checked. Enter Inspection and All Reports in Airplane Maintenance Logbook.
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Page 109 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Section 05-30 Maintenance Check Flight Preflight Inspection and Liberty XL-2 Post Inspection Check Flight are part of the maintenance procedures. Preflight Inspections Section 30-01 This inspection should be performed before all maintenance check flights by the pilot that will be making the flight.
Page 110 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE XL-2 P IBERTY NSPECTION HECK LIGHT Registration: Takeoff time: Takeoff fuel: Takeoff Date: Land time: weight: Pilot: Flight time: Landing fuel: Location: Engine time: Post Inspection Check Flight Procedure Step Step Description Pass Fail Initials Preflight –...
Page 111 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Post Inspection Check Flight Procedure Step Step Description Pass Fail Initials Engine Start Complete the following & accomplish the normal Engine Start checklist. Starter Annunciator – Verify light is illuminated when starter engaged & extinguished when released Alternator –...
Page 112 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Post Inspection Check Flight Procedure Step Step Description Pass Fail Initials Air work Conduct at safe altitude (normally ≥ 2,500ft AGL) Controllability and Stability Verify proper airplane response and control force 6.1.1 harmony. At cruise airspeed (110±10kts), wings level, trimmed 6.1.2...
Page 113 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Post Inspection Check Flight Procedure Step Step Description Pass Fail Initials Exhaust Gas Temperature (Normal 1000° to 1675°F) Fuel Pressure (Normal 25 to 98 PSIA) Oil Pressure (Normal 30 to 60 PSIG) Bus Voltage (Normal 12.0 to 14.3 Volts) Manifold Pressure (Normal 15 to 29.5 In.Hg.)
Page 114 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Post Inspection Check Flight Procedure Step Step Description Pass Fail Initials 10.6.1 Verify proper operation of the transponder. 10.6.2 Verify proper operation of the altitude encoder Descent, Approach and Landing Note the following items and accomplish normal checklists per the AFM.
Page 115 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Date Comments / Squawks Action Acceptance Date: Acceptance Pilot: Print Name Signature 05-30 P/N 135A-970-100 REVISION ~ Page 41 of 52...
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Page 117 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Section 05-40 Supplemental Inspections This section details other supplemental inspections that are in addition to those inspections shown in the prior sections of this chapter. Replacement of the Propeller Section 40-01 For complete propeller inspection requirements see manufactures requirements below.
Page 118 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE 50-Hour Engine Inspection Frequency Perform the 50-hour Inspection under the following two circumstances: • 25 hours after the 25-hour Initial Operation Inspection • After every 50 hours of operation 100-Hour (Annual) Engine Inspection Frequency Perform the 100-Hour Inspection under the following two circumstances: •...
Page 119 A qualified A & P mechanic, following an incidence of a hard landing, should perform this inspection. When a Liberty XL-2 has a hard landing, the airplane is subjected to stress levels beyond those anticipated during normal operation. The component might deform plastically.
Page 120 If the airplane has experienced a “crash”, the damage maybe too extensive to make the airplane airworthy The following are components that Liberty has identified as critical after a hard landing and need a detailed inspection. Inspection methods must be used, which are sufficient to determine whether an unsafe condition exists.
Page 121 Section 50-05 This section highlights the areas of the Liberty XL-2 for further Detailed Inspection. There are many aspects to evaluate when a Liberty XL-2 goes through a hard landing. Before making a detail inspection, the complete airplane should be inspected from Forward to Aft, and Starboard to Port.
Page 122 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Landing Gear: Main Under Carriage Port and Starboard Assembly: Inspect geometry of main gear legs. Check for any scrub marks on the tire along with its treads. Inspect main gear leg, inspect for any paint removal or flaking.
Page 123 Perform a detailed inspection by dismantling the airplane and inspecting all components mentioned before. An A&P Mechanic must record all discrepancies and report these to Liberty Aerospace, Inc. Customer Service. Upper and Lower Cowl: See Preliminary Assessment.
Page 124 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Landing Gear: Nose Under Carriage Assembly G. A.: Visually look into the structural symmetry of the nose gear along with castor weldment and bearing housing. In a standing position, upper and lower faces of the bearing housing should be parallel to the ground and side faces should be perpendicular.
Page 125 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE Tailplanes: Inspect for any shift in the tailplanes mass balance. Inspect every aspect of this part. Verify proper operation including the external and internal components. Verify doors lock and unlock properly. Remove hinges and re- Doors: install them.
Page 126 TIME LIMITS/MAINTENANCE CHECKS/INSPECTION INTERVALS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 05-50 P/N 135A-970-100 Page 52 of 52 REVISION C...
Page 127 DIMENSIONS AND AREAS XL-2 AIRPLANE CHAPTER 06 DIMENSIONS AND AREAS Chapter 06 P/N 135A-970-100 REVISION ~ Page 1 of 8...
Page 128 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 129 DIMENSIONS AND AREAS XL-2 AIRPLANE Table of Contents 06-00 ECTION ENERAL 00-01 ECTION HREE IEWS OF IRPLANE 00-02 ECTION IRPLANE IMENSIONS Chapter 06 P/N 135A-970-100 REVISION ~ Page 3 of 8...
Page 130 DIMENSIONS AND AREAS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 06 P/N 135A-970-100 Page 4 of 8 REVISION ~...
Page 131 DIMENSIONS AND AREAS XL-2 AIRPLANE Section 06-00 General This chapter has the overall dimensions of the airplane. Dimensions given in this chapter are in feet and inches (and tenths of inches if necessary for precision). Three Views of Airplane Section 00-01...
Page 132 DIMENSIONS AND AREAS XL-2 AIRPLANE Figure 06-3 (Reference Only) Top View of Airplane Dimensions P/N 135A-970-100 Page 6 of 8 REVISION ~...
Page 133 DIMENSIONS AND AREAS XL-2 AIRPLANE Airplane Dimensions Section 00-02 ITEM DIMENSION Overall Dimensions Wingspan (without anti-collision lights) 28 ft. 7 inches Wingspan (including anti-collision lights) 29 ft. 0 inches Airplane Length 20 ft. 4 inches Height 7 ft. 5 inches to top of Vertical Stabilizer...
Page 134 DIMENSIONS AND AREAS XL-2 AIRPLANE PAGE INTENTIONALLY LEFT BLANK P/N 135A-970-100 Page 8 of 8 REVISION ~...
Page 135 LIFTING AND JACKING XL-2 AIRPLANE CHAPTER 07 LIFTING AND JACKING Chapter 07 P/N 135A-970-100 REVISION E Page 1 of 14...
Page 136 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 137 LIFTING AND JACKING XL-2 AIRPLANE Table of Contents 07-00 ECTION ENERAL 00-01 ECTION EQUIRED QUIPMENT 07-10 ECTION IFTING AND ACKING 10-01 ECTION IFTING AND LOWER THE IRPLANE IFTING THE IRPLANE OWERING THE IRPLANE 10-02 ECTION ACKING THE IRPLANE ACKING THE...
Page 138 LIFTING AND JACKING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 07 P/N 135A-970-100 Page 4 of 14 REVISION ~...
Page 139: Section 07-00 General
LIFTING AND JACKING XL-2 AIRPLANE Section 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 –...
Page 140 LIFTING AND JACKING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 07-00 P/N 135A-970-100 Page 6 of 14 REVISION E...
Page 141: Section 07-10 Lifting And Jacking
LIFTING AND JACKING XL-2 AIRPLANE Section 07-10 Lifting and Jacking This section details the procedures for lifting and jacking the airplane. Lifting and Lower the Airplane Section 10-01 This section details the procedures for lifting and lowering the airplane. When lifting by the fuselage, as described below, the airplane is not supported laterally, and can sway.
Page 142: Lifting The Airplane
LIFTING AND JACKING XL-2 AIRPLANE IFTING THE IRPLANE Perform this procedure to lift the airplane Figure 07-2 Location of the Straps to Lift the Airplane Remove the upper engine cowling (see Chapter 71 – Power Plant). The forward nylon wide-webbing strap is best placed by looping it around the lower fuselage and securing it at the top, with the front edge of the strap at Station 40.
Page 143: Lowering The Airplane
LIFTING AND JACKING XL-2 AIRPLANE OWERING THE IRPLANE Perform this procedure to lower the airplane. Check the area under the airplane that it is clear. Be sure to station personnel to steady the wings and tail of the airplane. Lower the airplane to the ground.
Page 144: Section 10-02 Jacking The Airplane
LIFTING AND JACKING XL-2 AIRPLANE Jacking the Airplane: Section 10-02 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. For purposes of changing or servicing the nose landing gear...
Page 145 LIFTING AND JACKING XL-2 AIRPLANE ACKING THE IRPLANE ALL THREE WHEELS Perform this procedure to jack all three wheels of the airplane. Remove the fuselage belly panel Refer to Chapter 53- Fuselage for the procedure to remove the belly panel.
Page 146 LIFTING AND JACKING XL-2 AIRPLANE ACKING THE IRPLANE Perform this procedure to jack the airplane’s main gear only. Place a suitable jack under each main gear jack point. Figure 07-6 Main Gear Jacking Points Secure a weighted tail stand to the tail tie-down point.
Page 147: Lowering The Airplane
LIFTING AND JACKING XL-2 AIRPLANE OWERING THE IRPLANE Perform this procedure to lower the airplane. Check the area below the airplane that it is clear. Lower all jacks simultaneously until all wheels are on the ground. Remove all jacks and/or tail stand.
Page 148 LIFTING AND JACKING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 07-10 P/N 135A-970-100 Page 14 of 14 REVISION E...
Page 149 LEVELING AND WEIGHING XL-2 AIRPLANE CHAPTER 08 LEVELING AND WEIGHING Chapter 08 P/N 135A-970-100 REVISION ~ Page 1 of 16...
Page 150 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 151 LEVELING AND WEIGHING XL-2 AIRPLANE Table of Contents 08-00 ECTION ENERAL 00-01 ECTION EIGHT AND ALANCE AND THE ALCULATION FOR THE ENTER OF RAVITY 08-10 ECTION EIGHING AND ALANCING ROCEDURES 10-01 ECTION QUIPMENT EQUIRED MPTY EIGHT AND REPARATION EVELING OMENT...
Page 152 LEVELING AND WEIGHING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 08-00 P/N 135A-970-100 Page 4 of 16 REVISION ~...
Page 153 (adding the weights) and calculating the individual moments. The example shown here uses data from an actual XL-2 airplane. Use this information with the data derived from the procedures to calculate the CG of a specific serial number airplane.
Page 154 LEVELING AND WEIGHING XL-2 AIRPLANE Data Point (lbs) Net Weight Weight of non- Scale Reading airplane items Location of Weight Nose Wheel (N) Port Main Wheel (P) Starboard Main Wheel (S) Total Weight (W 1162 Table 08-1 Table Showing the Calculations for the Empty Weight of the Airplane Table 08-2 shows the weight data from Table 08-1, the station point for a given weight, and the calculation of the moment.
Page 155 • Plumb bob with string • Measuring Tape • Metal yard stick • Carpenter’s combination square The Aileron yoke blocks, P/N 135A-02-511, are available from Liberty Aerospace, Inc. Customer Service only. 08-10 P/N 135A-970-100 REVISION ~ Page 7 of 16...
Page 156 LEVELING AND WEIGHING XL-2 AIRPLANE MPTY EIGHT AND REPARATION The aircraft must be brought to its “empty” status to obtain the aircraft empty weight. This is accomplished as follows: Verify equipment installation is in accordance with aircraft equipment records. Run engine to ‘wet’ fuel system.
Page 157 LEVELING AND WEIGHING XL-2 AIRPLANE EVELING Perform this procedure to level the airplane in preparation for weighing the airplane. Perform Longitudinal Leveling procedure (on Page 14) or Alternate Method of Longitudinal Leveling (on Page 15) procedure of this chapter. Perform Lateral Leveling procedure (Page 16) of this chapter.
Page 158 LEVELING AND WEIGHING XL-2 AIRPLANE OMENT ETERMINATION To calculate the center of gravity (CG) location with respect to the reference datum, one must calculate each wheel moment with respect to the reference datum. To calculate the moment, the weight and the arm is needed. The weights are provided by the scales;...
Page 159 LEVELING AND WEIGHING XL-2 AIRPLANE Figure 08-2 Measurement of Distance Between STA 48.1 and Both Sides of Nose Gear Axle Mark floor at inside face of each main gear leg to represent port and starboard main wheels axle. Measure distance between port and starboard main wheels axle and mark representing STA 48.1.
Page 160 LEVELING AND WEIGHING XL-2 AIRPLANE IRPLANE EIGHING Perform this procedure to weigh the airplane. Perform the weighing of the airplane indoors, in a location free from air currents. Bring airplane to empty condition per Empty Weight and Preparation procedure on page 8 of this chapter.
Page 161 LEVELING AND WEIGHING XL-2 AIRPLANE Section 08-20 Leveling Leveling of the aircraft for the weight and balance determination must be conducted on aircraft scales. The port and starboard doorsills are to be used as a longitudinal support for the spirit level or digital protractor.
Page 162 LEVELING AND WEIGHING XL-2 AIRPLANE ONGITUDINAL EVELING Figure 08-4 Port Doorsill Place spirit level or digital protractor on top of port or starboard doorsill. Figure 08-5 Doorsills Used in Longitudinal Leveling Shim under tires to achieve longitudinal level. Repeat on opposite side of aircraft to confirm level has been achieved.
Page 163 LEVELING AND WEIGHING XL-2 AIRPLANE LTERNATE ETHOD OF ONGITUDINAL EVELING This alternate method of longitudinal leveling is presented as a matter of being possibly more convenient than the previous method. Both methods are equally acceptable. Place spirit level lengthwise along aircraft centerline on flat area between two seat backs.
Page 164 Remove a portion of the door seal from the lower edge of the door opening Place the beam level perpendicular to the aircraft’s centerline. Liberty Aerospace, Inc. recommends the use of aileron yoke blocks, P/N 135A-02-511, placed on the doorsill to support the beam level. The doorsill is a better surface for...
Page 165 TOWING AND TAXIING XL-2 AIRPLANE CHAPTER 09 TOWING AND TAXIING Chapter 09 P/N 135A-970-100 REVISION ~ Page 1 of 12...
Page 166 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 167 TOWING AND TAXIING XL-2 AIRPLANE Table of Contents 09-00 ECTION ENERAL 00-01 ECTION QUIPMENT AND CCESSORIES 09-10 ECTION OWING OSITIONING BY 09-20 ECTION AXIING 20-01 ECTION AXIING ROCEDURES AXIING ROCEDURES INGER RAKES AXIING ROCEDURES RAKES Chapter 09 P/N 135A-970-100 REVISION ~...
Page 168 TOWING AND TAXIING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 09 P/N 135A-970-100 Page 4 of 12 REVISION ~...
Page 169 Equipment and Accessories Section 00-01 Third party sources have developed a special accessory for towing the XL-2 airplane. This accessory allows for safe and secure towing by hand. Other tow bars can cause damage to the airplane. Liberty Aerospace, Inc. does not make any recommendations on the use of any tow bar from a third party source.
Page 170 TOWING AND TAXIING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 09-00 P/N 135A-970-100 Page 6 of 12 REVISION ~...
Page 171 TOWING AND TAXIING XL-2 AIRPLANE Section 09-10 Towing This section details the procedures for towing the airplane by hand. If attempting to tow or move the aircraft, caution should be exercised to assure the nose landing gear is not damaged. The best way of moving the aircraft is by positioning a person, or people, in safe positions around the aircraft, making sure not to apply excessive pressure to aircraft components.
Page 172 TOWING AND TAXIING XL-2 AIRPLANE OSITIONING BY Perform this procedure to position the airplane by hand. Remove forward and aft nose gear faring from nose gear assembly. See Figure 09-1 for an exploded view of the forward wheel fairing. Figure 09-1 Exploded view of the Forward Wheel Fairing If using a tow bar, attach the tow bar to the nose landing gear.
Page 173 XL-2 AIRPLANE Section 09-20 Taxiing On the ground, control of the Liberty XL-2 is from the brakes on the main gear. The left and right finger brakes (located on the cockpit center console) or the toe brakes (mounted on the rudder controls) control the brakes. Very tight turn radii can be achieved by operation of an individual brake.
Page 174 Enter cockpit; secure seat belt; release parking brake; check brake operation by pulling aft on both brake levers. Set the parking brake. Start engine (see Liberty XL-2 Approved Airplane Flight Manual). Release the parking brake. Use minimum required power to taxi the airplane to desired position.
Page 175 Enter cockpit; secure seat belt; release parking brake; check brake operation by pushing on the individual toe brake pedals. Set the parking brake. Start engine (see Liberty XL-2 Approved Airplane Flight Manual). Release the parking brake. Use minimum required power to taxi the airplane to desired position.
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Page 177 PARKING AND MOORING XL-2 AIRPLANE CHAPTER 10 PARKING AND MOORING Chapter 10 P/N 135A-970-100 REVISION ~ Page 1 of 12...
Page 178 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 179 PARKING AND MOORING XL-2 AIRPLANE Table of Contents 10-00 ECTION ENERAL 00-01 ECTION QUIPMENT EQUIRED 10-10 ECTION ARKING 10-01 ECTION ARKING ROCEDURES HORT ARKING ARKING 10-20 ECTION OORING YING Chapter 10 P/N 135A-970-100 REVISION ~ Page 3 of 12...
Page 180 PARKING AND MOORING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 10 P/N 135A-970-100 Page 4 of 12 REVISION ~...
Page 181 Equipment Required Section 00-01 The following is a list of equipment need to park and/or moor (tie down) the Liberty Aerospace, Inc. XL-2 airplane. • 4 wheel chocks • 3 screw-in mooring rings (left and right wing, and tail) •...
Page 182 PARKING AND MOORING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 10-00 P/N 135A-970-100 Page 6 of 12 REVISION ~...
Page 183 PARKING AND MOORING XL-2 AIRPLANE Section 10-10 Parking This section gives the details in parking the airplane. Parking Procedures Section 10-01 This section gives has the procedures for parking the airplane. If wheel brakes are hot from prolonged taxi, allow brakes to cool before setting parking brake.
Page 184 PARKING AND MOORING XL-2 AIRPLANE HORT ARKING Perform this procedure for short-term parking of the airplane. Taxi or tow airplane to desired parking position. Align nose of airplane into the wind. Ensure nose wheel is centered. In windy or gusty weather, moor (tie down) the airplane, see Section 10-20 Mooring (Tying Down) on page 11 of this chapter.
Page 185 PARKING AND MOORING XL-2 AIRPLANE ARKING Perform this procedure for long-term parking of the airplane. Perform the steps for short-term: parking. Moor (tie down) the airplane, see Section 10-20 Mooring (Tying Down) on page 11 of this chapter.. Install external rudder lock if available.
Page 186 PARKING AND MOORING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 10-10 P/N 135A-970-100 Page 10 of 12 REVISION ~...
Page 187 PARKING AND MOORING XL-2 AIRPLANE Section 10-20 Mooring (Tying Down) 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 the procedures for short and long term parking of the airplane.
Page 188 PARKING AND MOORING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 10-20 P/N 135A-970-100 Page 12 of 12 REVISION ~...
Page 189 MARKING AND PLACARDS XL-2 AIRPLANE CHAPTER 11 MARKING AND PLACARDS Chapter 11 P/N 135A-970-100 REVISION E Page 1 of 38...
Page 190 XL-2 AIRPLANE Copyright © 2010 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 191 MARKING AND PLACARDS XL-2 AIRPLANE Table of Contents 11-00 ECTION ENERAL 00-01 ECTION EASUREMENTS 00-02 ECTION EMOVAL AND NSTALLATION LACARD EMOVAL LACARD NSTALLATION 00-03 ECTION NTERNATIONAL ABELING 11-10 ECTION XTERIOR OLOR CHEMES AND ARKINGS 10-01 ECTION XTERIOR RAPHICS 11-20 ECTION...
Page 192 MARKING AND PLACARDS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 11 P/N 135A-970-100 Page 4 of 38 REVISION ~...
Page 193 MARKING AND PLACARDS XL-2 AIRPLANE Section 11-00 General This chapter describes exterior color schemes, markings, and placards. Also described are the location of placards on the exterior surfaces of the airplane and the location of placards and labels on interior surfaces. The use of placards is for identification and indication purposes.
Page 194 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-2 Location of the Waterline Reference Point and Station Reference Point Removal and Installation Section 00-02 The following are the procedures for removing and installing a placard from the airplane’s surface. 11-00 P/N 135A-970-100...
Page 195 MARKING AND PLACARDS XL-2 AIRPLANE LACARD EMOVAL Perform the following procedure to remove a placard from the airplane. Remove the damaged placard. On the wings and horizontal stabilizers (metal surfaces), remove the old placard from any metal surfaces, such as the wings, by gently heating the old placard with a hot air blower.
Page 196 MARKING AND PLACARDS XL-2 AIRPLANE LACARD NSTALLATION Perform this procedure to install a placard. Clean an area of sufficient size removing dirt, soil, and other foreign material with isopropyl alcohol. Peel off backing from self-adhesive vinyl placard. Mount placard in appropriate position and appropriate orientation.
Page 197 MARKING AND PLACARDS XL-2 AIRPLANE International Labeling Section 00-03 Some placards may be available in different languages depending on National Aviation Authorities’ requirements. Figure 11-3 shows an example of one of the placards that are available with different languages. The difference of language...
Page 198 MARKING AND PLACARDS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 11-00 P/N 135A-970-100 Page 10 of 38 REVISION E...
Page 199 Figure 11-6, and the Razor design, see Figure 11-7. Because of the design of the airplane, exterior graphics and the white base color of the airplane must use Liberty approved colors and decals. No other exterior graphic schemes are FAA approved and shall not be applied to the airplane.
Page 200 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-5 Exterior Graphics – Vanguard Design Figure 11-6 Exterior Graphics - Flow Design Figure 11-7 Exterior Graphics - Razor Design 11-10 P/N 135A-970-100 Page 12 of 38 REVISION A...
Page 201 MARKING AND PLACARDS XL-2 AIRPLANE Section 11-20 Exterior Placards, Labels and Data Plate This section describes the type and location of exterior placards. Located along both sides of the airplane, are various exterior placards. These placards provide information or instructions for proper operation of the airplane. This section has the following sections: Exterior Port Side, Exterior Starboard Side, Exterior Top Side, Exterior Bottom Side, and Exterior Data Plate.
Page 202 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-8 Location Part Number Details Item Number Located on the 135A-08-307-* exterior side of the * indicates language, window -1 is English only, Label is mounted -2 is English and Chinese such that it is...
Page 203 MARKING AND PLACARDS XL-2 AIRPLANE Location of Exterior Starboard Side Section 20-02 Placards In Figure 11-9, is the location of placards that are along the starboard side of the airplane. Table 11-3 is the detail explanation and examples of each of the exterior placards that are on the starboard side of the airplane.
Page 204 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-9 Location Part Number Placard Details Item Number 135A-08-340 Located centered in view through access hole on starboard side of 135A-08-397 the fuselage and is mounted on the Only on airplanes with a gross inside surface of weight of 1653 lbs.
Page 205 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-10 Item Location Part Number Placard Details Number 135A-09-313-* Located on the * indicates color, wing flaps near the -1 is black fuselage This is not a single placard but -2 is blue a series of letters.
Page 206 MARKING AND PLACARDS XL-2 AIRPLANE Location of Exterior Bottom Side Placards Section 20-04 In Figure 11-11, is the location of placards that are along the bottom of the airplane. Table 11-5 is the detail explanation and examples of each of the exterior placards that are on the bottom of the airplane.
Page 207 MARKING AND PLACARDS XL-2 AIRPLANE Location of Exterior Data Plate Section 20-05 The aircraft data plate, P/N 135A-00-501, is located on the port side of the airplane, below the horizontal stabilizer. See Figure 11-12 and Figure 11-13 for the location and an example of the aircraft data plate.
Page 208 MARKING AND PLACARDS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 11-20 P/N 135A-970-100 Page 20 of 38 REVISION E...
Page 209 MARKING AND PLACARDS XL-2 AIRPLANE Section 11-30 Location of Interior Placards and Labels This section details the location of interior placards and labels. The interior has the following subsections: Mid-Fuselage, Baggage Bay Bulkhead, Baggage Area, Interior Door, and Center Console.
Page 210 MARKING AND PLACARDS XL-2 AIRPLANE Baggage Area Section 30-03 The baggage area has three placards or labeling. See Figure 11-17 for location of the placards. See Table 11-6 for details and a description of the location of the placards. Figure 11-17...
Page 211 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-18 and Table 11-7 show the optional door windscreen vent. If there is no vent in the door windscreen (window), items 1 and 2 in Figure 11-18 and Table 11-7 are not included. Figure 11-18...
Page 212 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-18 Location Part Number Placard Details Item Number Located on the door 135A-10-386 The lettering is reverse color under the handle for clarity. Table 11-7 Placards on the Interior of the Starboard Side Door Figure 11-18 shows the location of the placards that are on the interior of the port side door.
Page 213 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-19 Location Part Number Placard Details Item Number Located on the 135A-08-321-* optional door screen * indicates language vent, if there is no vent in the door -1 is English only windscreen (window), -2 is English and Chinese...
Page 214 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-21 Location of the Ventilation Placard on the Center Console Figure 11-18 Location Part Number Placard Details Item Number Located on the center console seat 135A-08-346 back starboard side 135A-08-327-* * indicates language Located on the...
Page 215 MARKING AND PLACARDS XL-2 AIRPLANE Section 11-40 Interior Panels In the interior of the airplane, there are five panels with controls and/or indicators installed in them. These panels are the instrument panel, avionics panel, the CB (circuit breaker) panel, upper center console panel, and the lower center console.
Page 216 Figure 11-24. This placard instructs the pilot to avoid prolonged engine operation at speeds between 850 and 900 RPM. In the event of a VM1000FX display replacement this placard, Liberty Part Number 135A-80-325, must be applied to the replacement display bezel.
Page 217 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-25 Placard for the Avionics Panel The above pictorials are in reverse color for clarity. They are normally grey or beige with white lettering. CB (Circuit Breaker) Panel Section 40-03 The CB or Circuit Breaker panel is located on the starboard side of the instrument panel console, in front of the passenger’s seat.
Page 218 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-26 Placard for the CB (Circuit Breaker) Panel P/N 135A-80-303 The above pictorial is in reverse color for clarity. The CB panel placard is normally grey or beige with white lettering. In the above pictorial, the placard shown reflects the current version of the CB placard.
Page 219 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-27 Placard for the Upper Center Console Figure 11-28 No Smoking Decal, P/N 135A-09-305, for Airplanes Delivered to China The above pictorials are in reverse color for clarity. They are normally grey or beige with white lettering.
Page 220 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-29 Placards on the Lower Center Console The pictorials of Items 1 – 3a in Figure 11-29 and Table 11-10 are in reverse color for clarity. They are normally black with white lettering. Item...
Page 221 MARKING AND PLACARDS XL-2 AIRPLANE Item Location Part Number Placard Details Number Located on the starboard area of the lower center console, 135A-10-330 this plate is for airplanes equipped with hand brakes. Located on the starboard area of the lower center console,...
Page 222 MARKING AND PLACARDS XL-2 AIRPLANE THIS PAGE INTENTIONALLY LEFT BLANK 11-40 P/N 135A-970-100 Page 34 of 38 REVISION E...
Page 223 MARKING AND PLACARDS XL-2 AIRPLANE Section 11-50 Miscellaneous Placards and Labels This section is for other labels, placards, and other markings not associate with the above categories. Ball Drive Actuator Label Section 50-01 There is a caution label on the wiring of the ball drive actuator on the wing lock mechanism located on the port and starboard side of the space frame.
Page 224 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-32 Location of the anti-skid strip tape on the foot step Figure 11-33 Location of the anti-skid strip tape on the rudder pedals and the toe brake pedals Compass Correction Card Filling Section 50-03 The correction card, supplied with the compass, mounts to the underside of the compass.
Page 225 MARKING AND PLACARDS XL-2 AIRPLANE Figure 11-34 Example of the Compass Correction Card and Its Location on the Magnetic Compass 11-50 P/N 135A-970-100 REVISION ~ Page 37 of 38...
Page 226 MARKING AND PLACARDS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 11-50 P/N 135A-970-100 Page 38 of 38 REVISION ~...
Page 227 SERVICING XL-2 AIRPLANE CHAPTER 12 SERVICING Chapter 12 P/N 135A-970-100 REVISION E Page 1 of 16...
Page 228 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 229 SERVICING XL-2 AIRPLANE Table of Contents 12-00 ECTION ENERAL 12-10 ECTION EPLENISHING 10-01 ECTION YSTEM 10-02 ECTION EFUELING 10-03 ECTION YSTEM 10-04 ECTION ECOMMENDED ISCOSITY FOR EMPERATURE ANGE 10-05 ECTION ERVICING 10-06 ECTION RAINING 10-07 ECTION PPROVED EPLACEMENT 10-08 ECTION...
Page 230 SERVICING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 12 P/N 135A-970-100 Page 4 of 16 REVISION ~...
Page 231 SERVICING XL-2 AIRPLANE Section 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 232 SERVICING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 12-00 P/N 135A-970-100 Page 6 of 16 REVISION ~...
Page 233 Fuel System Section 10-01 Refueling: The Liberty XL-2’s fuel supply is contained in a single tank of 28 US gallons (106 liters) usable capacity. The tank is a welded aluminum tank located in the center fuselage. The tank cover forms the seatback structure for the left and right seats.
Page 234 SERVICING XL-2 AIRPLANE Figure 12-3 Location of Fuel Tank Sump Drain Use approved metal container(s) for defueling. Ground container to the engine exhaust pipe prior to starting defueling, and maintain ground connection until defueling is complete. Oil System Section 10-03 The engine oil is defined by the following references: •...
Page 235 Thereafter, only mineral oil, MIL-C-6529, TYPE ll, or Ashless Dispersant oils specifically approved by Teledyne Continental Motors for the IOF-240-B engine should be used. Liberty Aerospace, Inc. recommends recording the brand, type, and grade of oil currently used. Keep this information on board the airplane for reference by pilots and maintenance personnel.
Page 236 Total Aero DM 15W50 Union Oil Co. of California Union Aircraft Engine Oil HD Approved mineral oil MIL-C-6529 TYPE II Table 12-2 Table of Engine Oil Manufacturers Approved for the XL-2 Airplane 12-10 P/N 135A-970-100 Page 10 of 16 REVISION ~...
Page 237 Batteries: Section 10-10 The Liberty XL-2 has two recombinant-gas type (RG) batteries. Both batteries mount to the airplane aft of the baggage compartment in the fuselage. Access to the batteries is through the baggage compartment’s rear closeout bulkhead. The primary battery supplies aircraft electrical services such as engine starting, emergency power, and electrical system surge suppression.
Page 238 SERVICING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 12-10 P/N 135A-970-100 Page 12 of 16 REVISION ~...
Page 239 This chapter details specific areas and components that require periodic lubrication. In addition, it identifies areas that must not be lubricated. Lubrication Schedule Section 20-01 Table 12-3 shows the schedule for lubrication of different parts on the XL-2 airplane. Lubrication Schedule Aircraft Part...
Page 240 SERVICING XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 12-20 P/N 135A-970-100 Page 14 of 16 REVISION E...
Page 241 SERVICING XL-2 AIRPLANE Section 12-30 Unscheduled Servicing This section details those areas of the airplane that need periodic servicing; however, these areas are not on a specific schedule. Exterior Cleaning Section 30-01 Wash the exterior of the airplane with generous amounts of water and, if desired, a mild soap.
Page 242 SERVICING XL-2 AIRPLANE Check 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 243 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE CHAPTER 20 STANDARD PRACTICES AIRFRAME Chapter 20 P/N 135A-970-100 REVISION ~ Page 1 of 26...
Page 244 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 245 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Table of Contents 20-00 ECTION ENERAL 20-10 ECTION TANDARD RACTICES ECHANICAL 10-01 ECTION YPES 10-02 ECTION ORQUES 10-03 ECTION PECIAL ORQUES 10-04 ECTION ORQUE EASURING ETAILS 10-05 ECTION AFETY IRING AFETY ROCEDURE 10-06 ECTION OTTER...
Page 246 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 20 P/N 135A-970-100 Page 4 of 26 REVISION ~...
Page 247 Assembly. This chapter also describes standard practices for the electrical wiring, such as wire numbering and sizing, wire termination, splicing, and soldering. Specific fastener torque values appearing in individual Liberty Maintenance Manual chapters and sections may supersede the general torque values given in this chapter.
Page 248 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 20-00 P/N 135A-970-100 Page 6 of 26 REVISION ~...
Page 249 This section details the information for the hardware used on the Liberty Aerospace, Inc. XL-2 airplane. Bolt Types Section 10-01 Bolts used in the Liberty XL-2 conform to AN (Air Force-Navy) specification. In general, cadmium plating protects against corrosion. See Figure 20-1 for details on bolt markings. •...
Page 250 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Installation Torque for Bolt/Nut Combinations Nut installation torque values (lubricant free, cadmium plated Nominal Fastener Mid-Range Values Range (in-lbs) Min-Max Diameter (inches) (in-lbs) (90 KSI in bolts) 0.1640 17.5 15-20 0.1900 32.5 25-40 0.250 90-100 0.3125...
Page 251 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Special Torques Section 10-03 For specific torque requirements relating to Propeller Installations, please refer to manufacturer’s maintenance manual • Maintenance Manual for Sensenich W69EK7-63G Propeller Sensenich Wood Propeller Company Inc. Wood Propellers Installation Operation, & Maintenance Integral Flange Crankshafts WOOD-CF-REV-A.doc 5-20-04...
Page 252 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Figure 20-2 Main wheel caliper safety wire The purpose of safety wiring fasteners is to prevent fasteners from becoming loose during use. Thus, standard safety wiring patterns should be used to apply clockwise force to fasteners and secure them against inadvertent rotation in a counterclockwise direction.
Page 253 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE AFETY ROCEDURE Safety wiring or lockwiring is the securing together of two or more parts with lock- wire which shall be installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the wire.
Page 254 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Figure 20-3 Illustration of the Procedure to Use Lockwire Figure 20-4 Different Methods of Using Lockwire 20-10 P/N 135A-970-100 Page 12 of 26 REVISION D...
Page 255 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Cotter Pin/Split Pin Section 10-06 Never reuse cotter pins/split pins; always discard immediately upon removal. Figure 20-5 Split Pin Cotter pins/split pins are typically used to secure castellated (slotted) nuts against inadvertent rotation. The following procedure outlines the two methods of installing cotter/split pins.
Page 256 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE OTTER PLIT ROCEDURES There are two methods to install a cotter or split pin. Both methods are shown here. Method 1 Torque the castellated nut to the lowest value of torque as shown in the tables.
Page 257 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Tab Washers Section 10-07 Discard tab washer immediately upon removal. Never re-use a tab washer. Tab washers are used to prevent inadvertent fastener rotation by securing facets to fasteners to adjacent material or structure. A hole must be provided adjacent to the fastener location into which at least one tab of the tab washer can be bent.
Page 258 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE : (N SSEMBLY ERMANENT ASTENER NSTALLATION Prepare surfaces, if required, by cleaning with solvent to remove dirt, greases and other possible contaminants. Apply the compound to the surface(s) per manufacturer’s instructions. Install fasteners while the jointing compound is still tacky such that it will flow sufficiently under pressure.
Page 259 Wire Numbering Section 20-02 Each wire in the XL-2 airplane has a unique number. The number defines what circuit or system the wire belongs to, the route for the wire, the route subsection, the gauge of the wire, and if the wire is a travelling ground.
Page 260 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Sub System System Description Designation Lighting Power Distribution Avionics General Avionics Display Systems (glass cockpit) Avionics Garmin Avionics UPS Aviation Technologies Splice Solder Sleave Trim Flaps VM1000FX Annunciation, Stall Warning Table 20-5 Subsystem Prefix Designation for Wire Numbers...
Page 261 This section contains general splicing procedures for one-wire-to-one-wire or two- wire stub splicing, multiple-to-one wire or multiple-wire stub splicing, multiple-wire- to-multiple-wire splice. After the splicing procedures is the procedure to inspect the splice for compliance with Liberty Aerospace, Inc. specifications. 20-20 P/N 135A-970-100...
Page 262 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE IRE TO PLICES PLICES Perform the following procedure to make a one-wire-to-one-wire or two-wire stub splice Strip the wires to be spliced. If any conductor is to be folded back (to increase the effective cross-sectional area), strip the wire to twice the specified strip length.
Page 263 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Figure 20-14 Insulation Gap Center the sealing sleeve over the splice area as shown in Figure 20-15. Figure 20-15 Center Sealing Sleeve Heat sleeve from one end toward the other. For stub splices, start heating the splice at the end from which the wires exit.
Page 264 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE ULTIPLE PLICES AND ULTIPLE PLICE Perform the following procedure to make a multiple-to-one-wire or multiple-wire stub splice. Strip the wires to be spliced. If any conductor is to be folded back (to increase the effective cross-sectional area), strip the wire to twice the specified strip length..
Page 265 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Figure 20-19 Multiple Wire Crimp Splice Make sure that the multiple wires do not become crossed between the multiple-hole seal and the crimp splice. Center the sealing sleeve over the splice area as shown in Figure 20-20.
Page 266 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE ULTIPLE IRE TO ULTIPLE PLICES Perform the following procedure to make a multiple-to-one-wire or multiple-wire stub splice. Strip the wires to be spliced. If any conductor is to be folded back (to increase the effective cross-sectional area), strip the wire to twice the specified strip length..
Page 267 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE Figure 20-24 Multiple Hole Seal Crimp the wires in the crimp splice as shown below. Make sure that the multiple wires do not become crossed between either one of the multiple-hole seals and the crimp splice.
Page 268 STANDARD PRACTICES AIRFRAME XL-2 AIRPLANE NSPECTION OF THE PLICE Perform this procedure to inspect the splice after completing the splice. The following set of figures illustrate acceptable and unacceptable splices. Figure 20-27 Acceptable Figure 20-28 Unacceptable – Insufficient Heat Figure 20-29...
Page 269 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE CHAPTER 21 ENVIRONMENTAL SYSTEMS Chapter 21 P/N 135A-970-100 REVISION ~ Page 1 of 40...
Page 270 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 271 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Table of Contents 21-00 ECTION ENERAL 21-20 ECTION ISTRIBUTION YSTEMS 20-01 ECTION RESH ISTRIBUTION YSTEM 20-02 ECTION ERIODIC AINTENANCE 20-03 ECTION RESH ISTRIBUTION YSTEM ROCEDURES RESH ISTRIBUTION YSTEM NSPECTION 20-04 ECTION RESH ISTRIBUTION YSTEM ROUBLESHOOTING UIDE...
Page 272 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 21 P/N 135A-970-100 Page 4 of 40 REVISION ~...
Page 273 XL-2 AIRPLANE Section 21-00 General The heating and cooling system of the XL-2 is by means of a passive system, (no thermostatic control). Air circulation controls are located in the instrument console on the port (pilot) and starboard (co-pilot) side of the cockpit.
Page 274 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 21-00 P/N 135A-970-100 Page 6 of 40 REVISION ~...
Page 275 XL-2 AIRPLANE Section 21-20 Distribution Systems The Liberty XL-2 provides a fresh air system and a cabin heat system incorporating a wind screen defogging feature. Fresh air and heated air are distributed by means of separate systems. This section addresses each of these systems.
Page 276 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE RESH ISTRIBUTION YSTEM NSPECTION The following procedure performs Fresh Air Distribution System Inspection. Refer to troubleshooting guide at the end of the section for corrective action. Inspect port NACA duct for cracks, chipped paint or debris.
Page 277 Component installations are divided between the engine compartment and cabin of the XL-2 aircraft. In order to service the system access to the engine compartment, cabin and lower fuselage areas are required. Refer to the chapters referenced in procedures to follow for access.
Page 278 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE ERODUCT EMOVAL ROCEDURE This removal procedure applies to all Aeroduct installations in the engine cell and cabin. Repeat the procedure for each section of the distribution system removed. Position the master switch OFF. Position FADEC Power Switch A and B - OFF –...
Page 279 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE ERODUCT NSTALLATION ROCEDURE This installation procedure applies to all Aeroduct installations in the engine cell and cabin. Repeat the procedure for each section of the distribution system installed. Position the master switch OFF. Position FADEC Power Switch A and B - OFF –...
Page 280 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE ONNECTOR REMOVAL This procedure performs removal of the four way tube connector assembly located below the center console. Position the master switch OFF. Position FADEC Power Switch A and B - OFF – Remove belly panel in accordance with Chapter 53 – Fuselage For the following steps, refer to Figure 21-2 for location of components Locate and loosen the forward 2 inch Aeroduct hose clamp.
Page 281 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE ONNECTOR NSTALLATION This procedure performs removal of the four way tube connector assembly located below the center console. Position the master switch OFF. Position FADEC Power Switch A and B - OFF – For the following steps, refer to Figure 21-2 for location of components Do not over tighten the hose clamps.
Page 282 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EATING AND EFOGGING ISTRIBUTION YSTEM PERATIONAL HECK NSPECTION The following procedure may be performed on condition or in support of maintenance tasks called for in Chapter 05. For corrective actions refer to the heating and defogging distribution system troubleshooting guide section.
Page 283 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Heating and Defogging Distribution Section 20-08 System Troubleshooting Guide This section contains a guide to troubleshooting issues with the heating and defogging distribution system. Complaint Possible Cause Remedy • Tube abraded or holed • Replace Aeroduct Tube •...
Page 284 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE THIS PAGE LEFT INTENTIONALLY BLANK 21-20 P/N 135A-970-100 Page 16 of 40 REVISION ~...
Page 285 XL-2 AIRPLANE Section 21-40 Heating and Defogging System When so equipped, the Liberty XL-2 heating and defogging system provides warm air to the aircraft cabin for crew comfort and to the wind screen condensation removal. The system as depicted in Figure 21-3 is passive containing no boost fan components.
Page 286 Component installations are divided between the engine compartment and cabin of the XL-2 aircraft by a cabin heat box assembly affixed to the firewall blanket assembly. In order to service the system access to the engine compartment, cabin and lower fuselage areas are required.
Page 287 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE XCHANGER HROUD EMOVAL Perform this procedure to remove the heat exchanger shroud. Refer to Figure 21-5 during this procedure. Figure 21-5 Heat Exchanger Hardware Position the master switch - OFF. Position FADEC Power Switch A and B - OFF.
Page 288 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE XCHANGER HROUD NSTALLATION Perform this procedure to install the heat exchanger shroud. EFORE INSTALLING THE HEAT EXCHANGER SHROUD INSPECT THE ENTIRE SURFACE OF THE COLLECTOR MUFFLER FOR CRACKS SE A MIRROR TO INSPECT ALL SURFACES ON THE...
Page 289 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EATING YSTEM PERATIONAL HECK AND NSPECTION The following procedure may be performed on condition or in support of maintenance tasks called for in Chapter 05. For corrective actions refer to the heating system troubleshooting guide section.
Page 290 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Start the aircraft engine in accordance with Aircraft flight manual procedures. Pull the center console located cabin heat control to the open position. Open the cabin heat vent valves. Run up the engine to 2000 RPM and verify warm air flow out of the cabin heat vent valves.
Page 291 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Heating System Troubleshooting Guide Section 40-04 This section contains a guide to troubleshooting issues with the heating system. Complaint Possible Cause Remedy • Damaged or collapsed • Replace Aeroduct tube • Disconnected heating • Connect Aeroduct tube system Aeroduct tube •...
Page 292 Figure 21-7 Defog Louvers The Liberty XL-2 airplane has a demist cloth which must be used during ground operations over the cabin heat defogging system. Periodic Maintenance...
Page 293 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EFOGGING EMOVAL Perform this procedure to remove the defogging duct. Figure 21-8 Defogging System Position the master switch - OFF. Position FADEC Power Switch A and B - OFF Remove belly panel in accordance with the applicable section of Chapter 53 –...
Page 294 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EFOGGING NSTALLATION Perform this procedure to install the defogging duct. Position the master switch - OFF. Position FADEC Power Switch A and B - OFF. Slide the 1 inch Aeroduct tube up from the four way tube connector assembly into the instrument console.
Page 295 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EFOGGING YSTEM PERATIONAL HECK AND NSPECTION The following procedure may be performed on condition or in support of maintenance tasks called for in Chapter 05. For corrective actions refer to the defogging system troubleshooting guide section.
Page 296 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Defogging System Troubleshooting Guide Section 40-08 This section contains a guide to troubleshooting issues with the defogging system. Complaint Possible Cause Remedy • Damaged or collapsed • Replace defogger Aeroduct tube • Disconnected defogger • Connect Aeroduct tube Aeroduct tube •...
Page 297 XL-2 AIRPLANE Section 21-50 Temperature Control: Cabin temperature control in the XL-2 is provided by means of manual controls incorporated in the fresh air vent system and the cabin heat system. Fresh air is provided by the opening of vent valves located in the port and starboard sides of the instrument console as shown in Figure 21-9 below.
Page 298 Periodic Maintenance Section 50-01 Periodic Heating System maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Temperature Control Procedures...
Page 299 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE ABIN ALVE EMOVAL This procedure performs removal of the heat system vent valve assemblies. This procedure may be applied to either heat vent valve removal required. Position the master switch - OFF. Position FADEC Power Switch A and B - OFF.
Page 300 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE ABIN ALVE NSTALLATION This procedure performs installation of the heat system vent valve assemblies. This procedure may be applied to either heat vent valve installation required Position the master switch - OFF. Position FADEC Power Switch A and B - OFF If not already performed, remove the vent valve assembly locking ring.
Page 301 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EMOVAL Perform this procedure to remove the heat box from the airplane. During this procedure, refer to Figure 21-13. Position the master switch - OFF. Position FADEC Power Switch A and B - OFF. Remove upper and lower cowling in accordance with applicable sections of Chapter 71 –...
Page 302 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE NSTALLATION Perform this procedure to remove the heat box from the airplane. During this procedure, refer to Figure 21-13. Position the master switch - OFF. Position FADEC Power Switch A and B - OFF. Ensure all electrical switches are off.
Page 303 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EATER ABLE EMOVAL Perform this procedure to remove the heater cable from the airplane. Position the master switch - OFF. Position FADEC Power Switch A and B - OFF. Remove upper cowling. Refer to Chapter 71 – Power Plant.
Page 304 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Carefully pull the center console panel out. Figure 21-15 Heater Cable Assembly Remove the nut and washer as shown in Figure 21-15. Carefully work the cable up and out of the center console of the airplane.
Page 305 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EATER ABLE NSTALLATION Perform this procedure to install a heater cable. Position the master switch - OFF. Position FADEC Power Switch A and B - OFF Remove upper cowling. Refer to Chapter 71 – Power Plant.
Page 306 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE EMPERATURE ONTROL PERATIONAL HECK AND NSPECTION The following procedure may be performed on condition or in support of maintenance tasks called for in Chapter 05. For corrective actions refer to the defogging system troubleshooting guide section.
Page 307 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE Temperature Control Troubleshooting Section 50-03 Guide This section contains a guide to troubleshooting issues with temperature control system. The fresh air, heating and defog systems temperature control are addressed here. Complaint Possible Cause Remedy • Damaged or collapsed •...
Page 308 ENVIRONMENTAL SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 21-50 P/N 135A-970-100 Page 40 of 40 REVISION ~...
Page 309 COMMUNICATIONS XL-2 AIRPLANE CHAPTER 23 COMMUNICATIONS Chapter 23 P/N 135A-970-100 REVISION D Page 1 of 42...
Page 310 XL-2 AIRPLANE Copyright © 2010 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 311 COMMUNICATIONS XL-2 AIRPLANE Table of Contents 23-00 ECTION ENERAL 23-10 ECTION PEECH OMMUNICATIONS 10-01 GNS430 COM/NAV/GPS ECTION ARMIN 10-02 GNS 530 COM/NAV/GPS ECTION ARMIN 10-03 GNS 430W GNS 530W COM/NAV/GPS WAAS ECTION ARMIN 10-04 SL30 COM/NAV R ECTION ARMIN ADIO...
Page 312 COMMUNICATIONS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 23 P/N 135A-970-100 Page 4 of 42 REVISION D...
Page 313 XL-2 AIRPLANE Section 23-00 General The XL-2 has a Garmin VHF radio system, used for communication between the airplane and a ground station or between airplanes. The system operates in the frequency ranges of 118.000 to 136.975 MHz, and has 760 channels with a separation of 25 kHz.
Page 314 COMMUNICATIONS XL-2 AIRPLANE Figure 23-1 Typical Radio Installation on the left, is the GNS530/430 typical installation, on the right, is the GNS 430W/SL30 typical installation An avionics upgrade option is available to configurations listed above that replaces GNS 430 and GNS 530 COM/NAV/GPS units with GPS WAAS (Wide Area Augmentation System) capable GNS 430W and GNS 530W COM/NAV/GPS units.
Page 315 COMMUNICATIONS XL-2 AIRPLANE COM 1 COM 2 Figure 23-3 Communications Equipment Placement The alternator, and/or battery provide power for the avionics. The power goes through the Avionics Master switch and the COM circuit breaker. There is a dedicated circuit breaker for each radio. The size of circuit breaker matches the radio option installed.
Page 316 COMMUNICATIONS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 23-00 P/N 135A-970-100 Page 8 of 42 REVISION ~...
Page 317 GNS 430 transceiver can be in either the COM 1 or COM 2 stack position of the avionics panel depending on the radio option package installed. The description of the NAV and GPS subsystem may be found in Liberty Maintenance Manual Chapter 34-Navigation and Pitot/Static.
Page 318 COMMUNICATIONS XL-2 AIRPLANE The Garmin user guide and installation manual for the GNS 430 COM/NAV/GPS receiver has additional information on the control functions and features. Garmin GNS 530 COM/NAV/GPS Section 10-02 The GNS 530 COM/NAV/GPS transceiver provides radio communication between pilot and ground stations.
Page 319 COMMUNICATIONS XL-2 AIRPLANE The Garmin user guide and installation manual for the GNS 530 COM/NAV/GPS receiver has additional information on the control functions and features. Garmin GNS 430W and GNS 530W Section 10-03 COM/NAV/GPS WAAS The GNS 430W and 530W represent upgraded versions of the GNS 430 and GNS 530 units described above.
Page 320 Periodic Maintenance Section 10-07 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. VHF Transceiver Procedures Section 10-08 This section contains the removal and installation procedures.
Page 321 COMMUNICATIONS XL-2 AIRPLANE RANSCEIVER EMOVAL Perform the following procedure to remove the transceiver. Use this procedure for any of the radios installed in the avionics panel. Check that both aircraft battery switch and avionics master switch are OFF. Insert hex key (“3/32” Allen wrench”) into hole in faceplate of the radio and rotate counterclockwise until the retaining claw is released.
Page 322 COMMUNICATIONS XL-2 AIRPLANE RANSCEIVER NSTALLATION Perform the following procedures to install the transceiver. Use this procedure for any of the radios installed in the avionics panel. Check that both aircraft battery switch and avionics master switch are OFF. Check mating connectors on rear of radio and in mounting tray to check the integrity of all connections.
Page 323 EMOVAL Perform the following procedure to remove the avionics panel from the airplane. Liberty Aerospace, Inc. recommends performing this procedure while sitting in the pilot’s seat. Have the block of soft foam cushioning for the avionics panel in your lap that it covers the yoke assembly.
Page 324 COMMUNICATIONS XL-2 AIRPLANE Figure 23-8 Avionics Panel Showing the Location of the Screws Disconnect the connectors P5354 and P5355 from the altitude encoder. Disconnect the transponder antenna cable ATXP01 from the transponder tray. Disconnect the marker beacon antenna cable AMB01B from the cable AMB01A.
Page 325 COMMUNICATIONS XL-2 AIRPLANE VIONICS ANEL NSTALLATION Perform the following procedure to install the avionics panel. Retrieve the avionics panel removed in step 5 in the procedure Avionics Panel on Page 15. Connect J41 to P41 on the bracket on the right side of the power distribution harness.
Page 326 COMMUNICATIONS XL-2 AIRPLANE RANSCEIVER PERATION HECK AND NSPECTION Upon completing the installation of the transceiver, perform an operational check of the radio per the Garmin Ltd. OEM installation manual Post Installation Checkout procedure. Refer to Table 23-2 for applicable manual and section. In all cases, use the latest manual version.
Page 327 COMMUNICATIONS XL-2 AIRPLANE Troubleshooting Guide Section 10-09 Table 23-3 gives a basic troubleshooting guide for the Garman radios. Complaint Possible Cause Remedy • Repair Defective power supply wiring • Replace in accordance with Defective COM circuit breaker Liberty Maintenance Unable to transmit or receive;...
Page 328 COMMUNICATIONS XL-2 AIRPLANE The Liberty XL-2 uses one of two model COM/NAV/GPS antennas. The first is a model CI 2480-200 manufactured by Comant Industries. This model will support the GNS 430 and GNS 530 model NAV/COM/GPS (non-WAAS). This model antenna is designed for standard GPS radios. It is not able to support the higher precision requirements of GNS 430W and GNS 530W WAAS capable NAV/COM systems.
Page 329 Section 10-12 For the two models of COM/NAV/GPS antennas that may be installed on the Liberty XL-2 inspection procedures are performed to determine if physical damage or deterioration has occurred that could degrade antenna performance. Antenna removal and replacement procedures are provided in the event replacement of damaged antenna is required.
Page 330 COMMUNICATIONS XL-2 AIRPLANE CI 2480-200 A ODEL NTENNA EMOVAL Perform this procedure to remove the model CI 2480-200 Antenna. Refer to Figure 23-10 and Figure 23-11 during this procedure. This section has removal and installation procedures for the COM/NAV/GPS antennas. Perform the following removal and installation procedures in the event there is an issue with the COM/NAV/GPS antenna.
Page 331 COMMUNICATIONS XL-2 AIRPLANE Figure 23-11 View of the Underside of the Forward COM/NAV/GPS Antenna Position aircraft master switch to OFF. Install a tail stand underneath the tail section of the airplane. Connect an ESD wrist straps to a convenient chassis ground.
Page 332 COMMUNICATIONS XL-2 AIRPLANE Do not use any type of prying device to remove the antenna from the fuselage as this may cause damage to the fuselage. Apply a gentle rocking motion and twisting motion to the antenna body to release bonding material and remove the antenna from the upper fuselage.
Page 333 COMMUNICATIONS XL-2 AIRPLANE CI 2480-200 A ODEL NTENNA NSTALLATION Perform this procedure to install the model CI 2480-200 Antenna. This section has removal and installation procedures for the COM/NAV/GPS antennas. Perform the following removal and installation procedures in the event there is an issue with the COM/NAV/GPS antenna.
Page 334 Clean the surface with acetone and clean, lint free rags. Do not allow the acetone to air dry on the bonding surfaces. Dry the solvent using clean, lint free rags. Liberty Aerospace, Inc. recommends the use of two hands, one with a solvent dampened rag, and one following with a dry rag.
Page 335 COMMUNICATIONS XL-2 AIRPLANE Silastic, RTV or Silicone-Based sealing/caulking compounds are not to be used around the base or over the screw fillets. The high dielectric content of these materials distort satellite reception at low angles of elevation. Figure 23-13 COM/GPS Antenna Conductive Sealant (bottom view) Remove the protective ESD plugs.
Page 336 COMMUNICATIONS XL-2 AIRPLANE CI 2580-200 A ODEL NTENNA EMOVAL Perform this procedure to remove the model CI 2580-200 Antenna. Refer to Figure 23-14 and Figure 23-15 during this procedure. This section has removal and installation procedures for the COM/NAV/GPS antennas. Perform the following removal and installation procedures in the event there is an issue with the COM/NAV/GPS antenna.
Page 337 COMMUNICATIONS XL-2 AIRPLANE Examine the screws used to mount the antenna to the fuselage. If the screws are the socket cap screw type, then replace the screws with #8-32 flat head screws. Figure 23-15 View of the Underside of the COM/GPS Antenna Position aircraft master switch to OFF.
Page 338 COMMUNICATIONS XL-2 AIRPLANE Do not use any type of prying device to remove the antenna from the fuselage as this may cause damage to the fuselage. Apply a gentle rocking motion and twisting motion to the antenna body to release bonding material and remove the antenna from the fuselage.
Page 339 COMMUNICATIONS XL-2 AIRPLANE CI 2580-200 A ODEL NTENNA NSTALLATION Perform this procedure to install the model CI 2580-200 Antenna. This section has removal and installation procedures for the COM/NAV/GPS antennas. Perform the following removal and installation procedures in the event there is an issue with the COM/NAV/GPS antenna.
Page 340 Clean the surface with acetone and clean, lint free rags. Do not allow the acetone to air dry on the bonding surfaces. Dry the solvent using clean, lint free rags. Liberty Aerospace, Inc. recommends the use of two hands, one with a solvent dampened rag, and one following with a dry rag.
Page 341 COMMUNICATIONS XL-2 AIRPLANE Silastic, RTV or Silicone-Based sealing/caulking compounds are not to be used around the base or over the screw fillets. The high dielectric content of these materials distort satellite reception at low angles of elevation Figure 23-17 COM/GPS Antenna Conductive Sealant Remove the protective ESD plugs and place the antenna through the fuselage.
Page 342 NTENNA NSPECTION This procedure performs antenna inspections. Use this procedure in support of inspections identified in Liberty Maintenance Manual Chapter 05. Position the aircraft on a level surface Install a tail stand The following steps require access to the aft fuselage section. Failure to install a tail stand prior to accessing this area could result in damage to the aircraft and possible injury.
Page 343 COMMUNICATIONS XL-2 AIRPLANE Contaminates Unacceptable Contaminates Unacceptable Contaminates Unacceptable Around Antenna Base Around Antenna Base Around Antenna Base Unacceptable Unacceptable Unacceptable Antenna Base Clear Antenna Base Clear Antenna Base Clear of Contaminates of Contaminates of Contaminates Acceptable Acceptable Acceptable Figure 23-18 Antenna Contamination Inspection Check continuity between a mounting screw and the chassis for <...
Page 344 COMMUNICATIONS XL-2 AIRPLANE Troubleshooting Guide Section 10-13 Complaint Possible Cause Remedy • Replace In service wear Antenna cracked • Replace Impact damage • Replace Physical antenna damage • Repair Coax cable connection fault • Remove, inspect and Excess bonding resistance...
Page 345 GMA 340 AUDIO/ICS System Section 50-01 The Liberty XL-2 is equipped with a Garmin model GMA 340 audio panel as standard equipment. This unit provides central audio management for all possible avionics options. LED illuminated push buttons allow audio selection for both NAV and COM audio.
Page 346 One stereo music input is available at the audio jack panel located in the cabin ceiling. The XL-2 has audio panel installation is configured to make use of the pilot and co- pilot audio inputs only. Full intercom capability between these two stations is available.
Page 347 COMMUNICATIONS XL-2 AIRPLANE GMA 340 A UDIO ANEL EMOVAL This procedure performs audio pane until removal. Check that both aircraft battery switch and avionics master switch are OFF. Insert hex key (“3/32” Allen wrench”) into the hole in the faceplate of the audio/intercom panel.
Page 348 COMMUNICATIONS XL-2 AIRPLANE GMA 340 A UDIO ANEL NSTALLATION This procedure performs audio panel unit installation. Check that both the aircraft battery switch and avionics master switch are OFF. Check the mating connectors on the rear of the unit and in the mounting tray to check that no pins are bent or pushed back into the connector housing.
Page 349 COMMUNICATIONS XL-2 AIRPLANE GMA340 O PERATION HECK AND NSPECTION Perform an operational check of the audio panel per the Garmin Ltd. OEM installation manual Post Installation Checkout procedure. Refer to Table 23-4 for applicable manual and section. Use the latest manual version.
Page 350 COMMUNICATIONS XL-2 AIRPLANE Troubleshooting Guides Section 50-03 Refer to Table 23-5 and Table 23-6 to resolve issues with the Garmin audio/intercom system. The manuals in Table 23-5 are reference to the latest versions of the Garmin Ltd. Manuals. MODEL DOCUMENT...
Page 351 ELECTRICAL POWER XL-2 AIRPLANE CHAPTER 24 ELECTRICAL POWER Chapter 24 P/N 135A-970-100 REVISION E Page 1 of 64...
Page 352 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 353 ELECTRICAL POWER XL-2 AIRPLANE Table of Contents 24-00 ECTION ENERAL 24-10 ECTION LTERNATOR RIVE 10-01 ECTION ERIODIC AINTENANCE 10-02 ECTION LTERNATOR ROCEDURES LTERNATOR EMOVAL LTERNATOR NSTALLATION LTERNATOR ENSIONING LTERNATOR PERATION HECK AND NSPECTION 10-03 ECTION LTERNATOR ROUBLESHOOTING UIDE 24-30 DC G...
Page 354 ELECTRICAL POWER XL-2 AIRPLANE 24-60 DC E ECTION LECTRICAL ISTRIBUTION 60-01 DC P ECTION OWER ISTRIBUTION 60-02 ECTION ERIODIC AINTENANCE 60-03 ECTION IRCUIT REAKER AND ASTER ELAY ROCEDURES IRCUIT REAKER EMOVAL IRCUIT REAKER NSTALLATION ASTER ELAY EMOVAL ASTER ELAY NSTALLATION...
Page 355 ELECTRICAL POWER XL-2 AIRPLANE Section 24-00 General The airplane is equipped with a 14-volt (nominal) single-wire ground-return electrical system. A belt-driven alternator mounted at the front of the engine generates primary power. Two 12-volt maintenance-free recombinant-gas (RG) type lead-acid batteries are mounted in the aft fuselage as in Figure 24-1.
Page 356 ELECTRICAL POWER XL-2 AIRPLANE VM1000FX Engine Instrument Display Master Switch ALT/BAT ALT FAIL Annunciator Figure 24-2 Instrument panel showing the location of the ALT FAIL (Alternator Fail) indicator and the ALT/BAT switch However, the battery must be in the ON position to allow the alternator switch to be moved to the ON position.
Page 357 ELECTRICAL POWER XL-2 AIRCRAFT Figure 24-3 Fuselage Aft Battery Installation View Figure 24-4 Space Frame Installation View Maintenance operations performed by this chapter require adherence to procedures set forth in the chapter and with applicable sections of 14 CFR Part 43 Maintenance, Preventive Maintenance, Rebuilding, and Alterations to remain in compliance.
Page 358 ELECTRICAL POWER XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 24-00 P/N 135A-970-100 Page 8 of 64 REVISION E...
Page 359 LTERNATOR BELT REPLACEMENT REQUIRES REMOVAL AND REPLACEMENT OF THE PROPELLER MPROPER TORQUE OF PROPELLER BOLTS MAY CAUSE BOLT OR PROPELLER FAILURE AND RESULT IN INJURY OR DEATH See Liberty Maintenance Manual Chapter 61 for propeller removal / replacement procedures and correct bold torque values. 24-10 P/N 135A-970-100...
Page 360 ELECTRICAL POWER XL-2 AIRPLANE Periodic Maintenance Section 10-01 Alternator belt inspections take place at 100 hour and annual intervals. Perform the procedure Alternator Belt Operation Check and Inspection on page 14 of this chapter. Alternator Belt Procedures Section 10-02 This section details the procedures to remove, install, and inspect and check the alternator belt.
Page 361 Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF. Remove upper and lower engine cowling. Remove spinner and propeller in accordance with Liberty maintenance manual Chapter 61 procedures. Loosen nuts on alternator mounting bracket and alternator belt tension adjustment bolts.
Page 362 ELECTRICAL POWER XL-2 AIRPLANE LTERNATOR NSTALLATION Perform the following procedure to install the alternator belt. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF. Move (rotate) alternator as far as possible toward engine case.
Page 363 ELECTRICAL POWER XL-2 AIRCRAFT LTERNATOR ENSIONING Perform this procedure to tension the alternator belt to the proper tension. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF. Remove upper cowling.
Page 364 ELECTRICAL POWER XL-2 AIRPLANE LTERNATOR PERATION HECK AND NSPECTION Perform this procedure to do an operational check and inspection of the alternator belt. Refer to the Alternator Belt Troubleshooting Guide for corrective actions as required. Inspect alternator pulley, belt and engine pulley for wear or damage. Do not proceed if damage is present.
Page 365 ELECTRICAL POWER XL-2 AIRCRAFT Alternator Belt Troubleshooting Guide Section 10-03 This section contains a guide to troubleshooting issues with the alternator belt. Complaint Possible Cause Remedy Set belt tension, tighten and Tensioning arm bolt loose safety tension arm bolt and safety wire.
Page 366 ELECTRICAL POWER XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 24-10 P/N 135A-970-100 Page 16 of 64 REVISION ~...
Page 367 ELECTRICAL POWER XL-2 AIRCRAFT Section 24-30 DC Generation This section details the generation of DC voltage from the airplane’s engine. Alternator Section 30-01 The alternator (nominal capacity 60 amps maximum at 14.2 Vdc maximum) is mounted on the right side of the front of the engine. Maintenance operations are normally limited to removal and installation of the alternator for condition.
Page 368 ELECTRICAL POWER XL-2 AIRPLANE LTERNATOR EMOVAL Perform this procedure to remove the alternator from the airplane. Pull the BAT 1 (CB001) circuit breaker to OPEN. Pull the ALT Field (CB002) circuit breaker to OPEN. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF.
Page 369 ELECTRICAL POWER XL-2 AIRCRAFT LTERNATOR NSTALLATION Perform this procedure to install the alternator on to the airplane. Pull the BAT 1 (CB001) circuit breaker to OPEN. Pull the ALT Field (CB002) circuit breaker to OPEN. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF.
Page 370 ELECTRICAL POWER XL-2 AIRPLANE F3 R LTERNATOR EPLACEMENT Perform this procedure to remove the alternator from the airplane. Pull the BAT 1 (CB001) circuit breaker to OPEN. Pull the ALT Field (CB002) circuit breaker to OPEN. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF.
Page 371 ELECTRICAL POWER XL-2 AIRCRAFT There is a small rubber “O” ring gasket inside the fuse holder. This gasket should remain in side the large portion of the fuse holder, this is normal. If gasket come out or comes out on the smaller portion of the fuse, insert the gasket back in to the larger portion of the fuse holder.
Page 372 ELECTRICAL POWER XL-2 AIRPLANE LTERNATOR PERATION HECK AND NSPECTION Perform this procedure to do an operational check and inspection of the alternator. Refer to the Alternator Troubleshooting Guide for corrective actions as required. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF Remove upper cowling.
Page 373 ELECTRICAL POWER XL-2 AIRCRAFT Alternator troubleshooting guide Section 30-04 This section contains a guide to troubleshooting issues with the alternator. Complaint Possible Cause Remedy Alternator failed Replace ACU failed Replace Cabling, connectors, electrical Repair No power supplied by connections alternator with engine running;...
Page 374 ELECTRICAL POWER XL-2 AIRPLANE Alternator Control Unit (ACU) Section 30-05 The Alternator Control Unit (ACU) is located in the aft fuselage adjacent to the strobe light power supply. The unit does not require periodic maintenance. Adjustments are limited to a single regulation level control set on installation.
Page 375 ELECTRICAL POWER XL-2 AIRCRAFT (ACU) R LTERNATOR ONTROL EMOVAL Perform this procedure to remove the alternator control unit. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 376 ELECTRICAL POWER XL-2 AIRPLANE (ACU) I LTERNATOR ONTROL NSTALLATION Perform this procedure to install the alternator control unit. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 377 ELECTRICAL POWER XL-2 AIRCRAFT (ACU) O LTERNATOR ONTROL PERATION HECK NSPECTION Perform this procedure to do an operational check and inspection of the alternator control unit. Refer to the ACU Troubleshooting Guide for corrective actions as required. Install a tail stand Remove the cabin aft bulkhead access panel by removal of retaining screws.
Page 378 ELECTRICAL POWER XL-2 AIRPLANE ACU Status Annunciator (LED). Voltage adjustment access. Covered by protective plug. Figure 24-9 ACU Voltage Adjustment Using a jeweler’s screwdriver, make small adjustments to the ACU voltage control. Turn the control clockwise (CW) to increase voltage and counterclockwise (CCW) to decrease voltage.
Page 379 ELECTRICAL POWER XL-2 AIRCRAFT ACU Troubleshooting Guide Section 30-08 This section contains a guide to troubleshooting the Alternator Control Unit. Complaint Possible Cause Remedy Alternator failed Replace No power supplied by ACU failed Replace alternator with engine running; ALT FAIL warning light...
Page 380 Primary Battery Section 30-10 The Liberty XL-2 may be fitted with the Concorde model RG-25 or the Concord model RG-25XC as the primary aircraft battery. The Concorde RG-25, has a C1 rated capacity of 22 amp/hours while the Concorde RG-25XC offers a higher rated ®...
Page 381 ELECTRICAL POWER XL-2 AIRCRAFT Periodic Maintenance Section 30-11 Primary battery inspections take place at 100 hour and annual intervals. Perform the procedure Primary Battery Operation Check and Inspection on page 35 of this chapter. During removal and replacement operations care must be taken to assure separation of primary and secondary battery leads is maintained.
Page 382 ELECTRICAL POWER XL-2 AIRPLANE RIMARY ATTERY EMOVAL Perform this procedure to remove the primary battery from the airplane. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 383 ELECTRICAL POWER XL-2 AIRCRAFT RIMARY ATTERY NSTALLATION Perform this procedure to install the primary battery into the airplane. Verify that replacement battery is correct type. Perform the procedure Primary Battery Operation Check and Inspection on page 35 of this chapter.
Page 384 ELECTRICAL POWER XL-2 AIRPLANE Apply a thin coating of Dow Corning 4 (DC4) electrical insulating compound over the terminal/bolt assembly. Push in the BAT1 (CB001) to CLOSE. Position the split master switch BAT side to ON Verify OAT voltage meter function indication is within +/- 1 volt of operational check reading performed in step 2 above.
Page 385 ELECTRICAL POWER XL-2 AIRCRAFT RIMARY ATTERY PERATION HECK AND NSPECTION Perform this procedure to do an operational check and inspection of the primary battery. Refer to the Primary Battery Troubleshooting Guide for corrective actions as required. Perform primary battery removal as described in Primary Battery Removal shown on page 32 of this chapter.
Page 386 ELECTRICAL POWER XL-2 AIRPLANE Charge the battery using a constant potential capable charger at 14.1 volts until the charge current stabilizes for 1 hour Verify the battery did not become very hot, 55°C (130°F) or greater, during the charge process. Replace battery is temperature exceeds limit.
Page 387 ELECTRICAL POWER XL-2 AIRCRAFT Primary Battery Troubleshooting Guide Section 30-13 Use Table 24-5 as a guide in troubleshooting issues with the primary battery. Complaint Possible Cause Remedy Battery discharged charge battery Defective master switch Replace Defective battery contactor Replace Unable to connect the...
Page 388 ELECTRICAL POWER XL-2 AIRPLANE Complaint Possible Cause Remedy • Clean battery and wire terminals with stiff brush and contact cleaner Loss of corrosion insulating • Apply a thin coating of compound Terminal corrosion DC4, Dow Corning 4, electrical insulating compound over the...
Page 389 The secondary battery, providing backup power for the engine FADEC system, must be replaced at specific service intervals regardless of condition. See Liberty Maintenance Manual Chapter 04 limitations. During removal and replacement operations care must be taken to assure separation of primary and secondary battery leads is maintained.
Page 390 ELECTRICAL POWER XL-2 AIRPLANE ECONDARY ATTERY EMOVAL Perform the following procedure to remove the secondary battery from the airplane. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 391 ELECTRICAL POWER XL-2 AIRCRAFT ECONDARY ATTERY NSTALLATION Perform this procedure to install the secondary battery. Verify that replacement battery is correct type and that it is properly charged. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any...
Page 392 ELECTRICAL POWER XL-2 AIRPLANE ECONDARY ATTERY PERATIONAL HECK AND NSPECTION Perform the following procedure to do an operational check and inspection of the secondary battery. Refer to the Secondary Battery Troubleshooting Guide for corrective actions as required. Remove the secondary battery from the airplane per the procedure Secondary Battery Removal as shown on page 40 of this chapter.
Page 393 ELECTRICAL POWER XL-2 AIRCRAFT Secondary Battery Troubleshooting Guide Section 30-17 Refer to Table 24-7 for a guide to troubleshooting issues with the secondary battery. Complaint Possible Cause Remedy Battery discharged Charge battery Battery will not power FADEC Defective FADEC B switch Replace “B”...
Page 394 ELECTRICAL POWER XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 24-30 P/N 135A-970-100 Page 44 of 64 REVISION E...
Page 395 ELECTRICAL POWER XL-2 AIRCRAFT Section 24-60 DC Electrical Load Distribution This section details the DC electrical load distribution for the airplane. DC Power Distribution Section 60-01 DC power from the primary battery is routed to the main distribution bus through a 70-amp circuit breaker.
Page 396 ELECTRICAL POWER XL-2 AIRPLANE IRCUIT REAKER EMOVAL Perform this procedure to remove an individual circuit breaker from the circuit breaker panel. Pull circuit breaker BAT 1 (CB001) to OPEN. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF.
Page 397 ELECTRICAL POWER XL-2 AIRCRAFT Disconnect engine data processing unit cable connector PVM04 from DPU connector PVM04. Remove four (4) 6-32 screws holding the DPU mounting bracket to the circuit breaker panel assembly. See Figure 24-15 for the location of the DPU mounting screws.
Page 398 ELECTRICAL POWER XL-2 AIRPLANE IRCUIT REAKER NSTALLATION Perform this procedure to install an individual circuit breaker from the circuit breaker panel. Position replacement circuit breaker in panel location and install retention nut finger tight. Install circuit breaker bus bar screw and tighten to a torque of 9-12 in-lbs. If installing CB001, tighten the terminal bolt to a torque of 50 to 100 in-lbs.
Page 399 ELECTRICAL POWER XL-2 AIRCRAFT ASTER ELAY EMOVAL Perform this procedure to remove the master relay. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 400 ELECTRICAL POWER XL-2 AIRPLANE Locate relay K001 (master relay) on the aft baggage bay bulkhead. K001 RELAY Figure 24-18 Master Relay Location Figure 24-19 Master Relay Showing the Relay’s Connections Remove A1 terminal nut and slide ring terminals off the relay stud. Refer to Figure 24-19 for the location of the A1 terminal.
Page 401 ELECTRICAL POWER XL-2 AIRCRAFT ASTER ELAY NSTALLATION Perform this procedure to install the master relay. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 402 ELECTRICAL POWER XL-2 AIRPLANE Reconnect positive then the negative cable to airplane’s primary battery. Apply a torque of 70 in-lb ± 5 in-lbs. Install the aft baggage compartment closeout. Press circuit breaker BAT 1 (CB001) to CLOSE. Remove tail stand under the aircraft.
Page 403 ELECTRICAL POWER XL-2 AIRCRAFT IRCUIT REAKER AND ASTER ELAY PERATION HECK NSPECTION Perform the following procedure to do an operational check and inspection of the circuit breakers and master relay. Refer to the Master Relay Troubleshooting Guide for corrective actions as required.
Page 404 ELECTRICAL POWER XL-2 AIRPLANE Position the aircraft master switch to ON. Verify the master relay engages. Verify there is an indication of the correct battery voltage on the VM1000FX engine status display. Power on each of the systems and subsystems listed in the table above.
Page 405 ELECTRICAL POWER XL-2 AIRCRAFT Master Relay Troubleshooting Guide Section 60-04 Refer to Table 24-10 for a guide to troubleshooting issues with the master relay. Complaint Possible Cause Remedy Master switch fault Replace Master relay fault Replace No power to system...
Page 407 ELECTRICAL POWER XL-2 AIRCRAFT Avionics Power Distribution Section 60-05 Power is provided to avionics components from a separate avionics power bus. The avionics bus receives power from the main power distribution bus via a single 25-amp circuit breaker, and is controlled by an avionics power relay operated by an instrument panel avionics master switch.
Page 408 ELECTRICAL POWER XL-2 AIRPLANE Circuit Breaker Removal and Installation Section 60-06 The circuit breakers for the avionics are the same as the other circuit breakers mounted to the CB (Circuit Breaker) panel. The procedures to remove and install the circuit breakers for the avionic panel are the same as the other circuit breakers.
Page 409 ELECTRICAL POWER XL-2 AIRCRAFT VIONICS ASTER ELAY EMOVAL Perform this procedure to remove the avionics master relay. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF. Pull the BAT1 (CB001) circuit breaker to OPEN.
Page 410 ELECTRICAL POWER XL-2 AIRPLANE Figure 24-23 Avionics Master Relay Location Remove quick disconnects attached to avionics master relay K004 terminals Loosen and remove the 6-32 screw securing the relay to the circuit breaker panel. Retain this hardware for later installation.
Page 411 ELECTRICAL POWER XL-2 AIRCRAFT VIONICS ASTER ELAY NSTALLATION Perform this procedure to install the avionics master relay. Position replacement K004 relay on the circuit breaker panel rear assembly as show above. Secure relay K004 with one (1) 6-32 screw and washer removed previously.
Page 412 ELECTRICAL POWER XL-2 AIRPLANE VIONICS OWER ISTRIBUTION PERATION HECK NSPECTION Perform this procedure to do an operational check and inspection of the avionics power distribution. Refer to the Avionics Power Subsystem Troubleshooting Guide for corrective actions as required. Verify primary battery is fully charged. To verify the charge on the primary battery, refer to the procedure Primary Battery Operation Check and Inspection on page 35 of this chapter.
Page 413 ELECTRICAL POWER XL-2 AIRCRAFT System Sub-System System Sub-System FLAP VM1000 TRIM AUDIO COM 1 NAV 1 COM 2 AVIONICS NAV 2 XPNDR MASTER Table 24-12 Table indicating circuit breaker systems and sub systems Position the aircraft master switch to ON...
Page 414 ELECTRICAL POWER XL-2 AIRPLANE Avionics Power Subsystem Section 60-09 Troubleshooting Guide Refer to Table 24-13 for a guide in troubleshooting issues with the avionics power subsystem. Complaint Possible Cause Remedy Avionics master switch fault Replace Avionics master relay fault Replace...
Page 415 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE CHAPTER 25 EQUIPMENT AND FURNISHINGS Chapter 25 P/N 135A-970-100 REVISION D Page 1 of 68...
Page 416 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 417 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Table of Contents 25-00 ECTION ENERAL 25-10 ECTION LIGHT OMPARTMENT QUIPMENT 10-01 ECTION ASES AND ONTAINERS 25-50 ECTION ARGO OMPARTMENT 25-60 ECTION MERGENCY QUIPMENT 60-01 ECTION XTINGUISHER 60-02 ECTION XTINGUISHER OUNTING 60-03 ECTION XTINGUISHER NSPECTION...
Page 418 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 25 P/N 135A-970-100 Page 4 of 68 REVISION C...
Page 419 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Section 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. Figure 25-1 View of Aircraft Interior...
Page 420 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 25-00 P/N 135A-970-100 Page 6 of 68 REVISION ~...
Page 421 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Section 25-10 Flight Compartment Equipment 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 uses Velcro hook and loop fasteners to hold them in place.
Page 422 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 25-10 P/N 135A-970-100 Page 8 of 68 REVISION ~...
Page 423 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Section 25-50 Cargo Compartment The cargo (baggage) compartment is immediately aft of, and contiguous with, the flight compartment. Hook and loop fasteners secure the carpet to the floor of the cargo compartment. An access plate of composite material is in the cargo compartment floor.
Page 424 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 25-50 P/N 135A-970-100 Page 10 of 68 REVISION ~...
Page 425 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Section 25-60 Emergency Equipment The airplane comes equipped with a fire extinguisher, safety hammer, and an Emergency Locator Transmitter, ELT. The sections that follow discuss each of these items. Fire Extinguisher Section 60-01 Secured behind the co-pilot/passenger seat in the baggage compartment is the portable fire extinguisher.
Page 426 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Fire Extinguisher Inspection Section 60-03 Inspect the fire extinguisher on the intervals as shown in Chapter 5 – Time Limits of this manual. The following items are inspected. • Extinguisher is in its designated place •...
Page 427 Emergency Locator Transmitter Section 60-05 The Liberty XL-2 is fitted with an Emergency Locator Transmitter in the aircraft’s aft fuselage section above the secondary battery, with a fuselage-mounted antenna located on the top of the fuselage between the two COM/NAV/GPS antennas.
Page 428 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT A NTENNA EMOVAL Perform this procedure to remove the ELT antenna. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 429 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Figure 25-9 Exploded View of ELT Antenna Installations Remove the ELT antenna. If installing a replacement antenna later, cap and secure the cable end, cover the ELT antenna-mounting hole in the fuselage, and install the ELT antenna access cover.
Page 430 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT A NTENNA NSTALLATION Perform this procedure to install the ELT antenna. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 431 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT A NTENNA ABLE EMOVAL Perform this procedure to remove the ELT antenna cable. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 432 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT A NTENNA ABLE INSTALLATION Perform this procedure to install the ELT antenna cable. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 433 Section 60-08 Transmitter (ELT) The Liberty XL-2 can be equipped with an Ameriking model AK450, 121.5/243 MHz Emergency Locator Transmitter (ELT) like that shown in Figure 25-12. The location of the unit is in the rear fuselage directly above the secondary battery as shown in Figure 25-13.
Page 434 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT Antenna Location Location above the secondary battery Figure 25-13 Location of the Emergency Locator Transmitter and Antenna ELT Remote Switch ELT Remote Switch ELT Remote Switch ELT Remote Switch Figure 25-14 ELT Remote Switch Location...
Page 435 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Figure 25-15 ELT Installation Periodic maintenance requires an operational check of the ELT, however, avoid unnecessary ELT operational checks, as any operation of the ELT reduces its battery life. Periodic Maintenance Section 60-09 In the United States, minimum annual maintenance requirements for an ELT are in paragraph (d) of 14 CFR Part 91.207.
Page 436 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE All references to maintenance for the United States shall also apply to all ELT users outside of the US unless otherwise required by relevant national regulations. Compliance with these requirements for the 121.5/243 MHz ELT is part of Section 60-10, 121.5/243 MHz ELT Service Procedures, of this chapter.
Page 437: Elt Removal
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOVAL Perform this procedure to remove the ELT from the airplane. Take care when removing the ELT from its mounting. Removed improperly, the ELT can trigger a false emergency signal. Possible fines may be imposed if there is a false activation of an ELT.
Page 438 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Inspect ELT remote jack pins for damage or evidence of corrosion. Inspect ELT case and ELT Tray for cracks or other obvious damage. Inspect all installation metal parts for signs of corrosion. This completes the ELT Removal procedure.
Page 439: Elt Battery Removal
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT B ATTERY EMOVAL Perform this procedure to remove the ELT Battery. Take care when removing the ELT from its mounting. Removed improperly, the ELT can trigger a false emergency signal. Possible fines may be imposed if there is a false activation of an ELT.
Page 440: Elt Battery Installation
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT B ATTERY NSTALLATION Perform this procedure to install the ELT battery. Replacement batteries are Duracell MN1300 model cells. Each of the installed cells must all have the same replacement date markings. If installing new cells, record the battery replacement data.
Page 441: Elt Installation
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT I NSTALLATION Perform this procedure to install the Emergency Locator Transmitter. Take care when removing the ELT from its mounting. Removed improperly, the ELT can trigger a false emergency signal. Possible fines may be imposed if there is a false activation of an ELT.
Page 442: Elt Remote Control Switch Removal
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOTE ONTROL WITCH EMOVAL Perform this procedure to remove the ELT remote control switch. Position aircraft master switch to OFF. Verify the ELT remote switch activity LED is off. Remove four (4) 4-40 machine screws securing remote switch to the avionics panel.
Page 443 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOTE WITCH ATTERY EMOVAL AND NSTALLATION Perform this procedure to remove and install the ELT remote switch battery cell. Referring to Figure 25-18, remove three (3) retaining screws from the remote switch body to access the battery compartment.
Page 444 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Insert battery, Duracell model DL 1/3NB, with the polarity shown in Figure 25-18 above. Replace the top half of the remote unit and replace the three (3) retaining screws removed previously. Tighten two switch-retaining nuts loosened earlier.
Page 445: Elt Remote Switch Installation
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOTE WITCH NSTALLATION Perform this procedure to install the ELT remote switch. Place aircraft master switch in the OFF position. Locate and connect remote cable to switch jack. Refer to Figure 25-17. Slide switch assembly into the avionics panel Install four (4) 4-40 machine screws securing the remote switch to the avionics panel.
Page 446: Elt Operational Check And Inspection
Perform this procedure to perform an operational check and inspection. Procedure to follow provides inspection and maintenance required to comply with 100 hour and annual ELT inspection interval requirements, specified in Liberty maintenance manual Chapter 05 – Time Limits/Maintenance Checks/Inspection Intervals.
Page 447 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Figure 25-19 121.5/243 Mhz Antenna Inspection Inspect the avionics panel mounted ELT remote switch face for condition, evidence of damage or other factors affecting proper ELT operation. If performing the 100-hour inspection proceed with step 20 else proceed with step 12 to complete an annual inspection.
Page 448 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Perform the ELT Remote Switch Battery Cell Removal and Installation procedure shown on page 29 of this chapter. Perform the ELT Remote Switch Installation procedure shown on page 31 of this chapter. Perform the ELT 121.5 MHz Transmitter Test procedure shown on page 36 of this chapter.
Page 449: Elt G-Switch Check
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT G-S WITCH HECK Perform this procedure to check the function of the G-switch in the ELT. The G-switch is a simple electromechanical switch intended to operate when an abrupt change of direction occurs. Test the switch by applying a force of 3 G’s (Gravity) or more in a rearward direction.
Page 450 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT 121.5 MH RANSMITTER Perform this procedure to test the ELT 121.5 MHz transmitter. Start and complete the following test between the top of the hour and five (5) minutes past the hour. This is the only time during each hour to perform this test without alerting monitoring agencies.
Page 451 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT F ESET EMOTE WITCH Perform this procedure to reset the ELT from the remote switch. To reset the ELT, locate the remote switch located in the avionics panel below the transponder. See Figure 25-21 for the location of the reset button.
Page 452 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT F ESET OCAL ONTROLS Perform this procedure to reset the ELT from the local controls. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 453 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE 121.5/243 MHz ELT Troubleshooting Guide Section 60-11 Use Table 25-3 as a guide to troubleshoot issues with the ELT. Symptom Likely Cause Action Inspect wiring and repair as required. Wiring error or frayed wires Remote ELT switch...
Page 454 Section 60-12 Transmitter (ELT) The Liberty XL-2 can be equipped with an Artex model ME406 Emergency Locator Transmitter (ELT) like that shown in Figure 25-23. This unit is qualified under TSO- C126 for ELT’s capable of transmitting identification data on 406 MHz. This unit is also qualified to transmit an emergency sweep tone on 121.5 MHz.
Page 455 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT Antenna Location Location above the secondary battery Figure 25-24 ELT Location ELT Status LED ELT Remote Switch ELT Remote Switch Figure 25-25 ELT Remote Switch Location 25-60 P/N 135A-970-100 REVISION D Page 41 of 68...
Page 456 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Figure 25-26 ELT Installation ELT function is automatic. In the event of sudden impact or excessive deceleration, it will broadcast an internationally recognized distress signal on frequencies of 121.5 MHz and 406 MHz. Transmission of a standard sweep tone on 121.5 MHz continues until battery power is exhausted.
Page 457 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE In addition, to ensure continued reliability and airworthiness, inspect the ELT for damage and wear caused by age, exposure to the elements, vibration, or other causes. Inspections are to take place annually per FAR part 91.409. FAR 43, Appendix D(i).
Page 458 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOVAL Perform this procedure to remove the ELT from the airplane. Take care when removing the ELT from its mounting. Removed improperly, the ELT can trigger a false emergency signal. Possible fines may be imposed if there is a false activation of an ELT.
Page 459 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Evidence of damage requires inspection, repair, or replacement by a repair station qualified for TSO C126 ELT units. Do not install an ELT with evidence of damage. Inspect ELT case and ELT Tray for cracks or other obvious damage.
Page 460 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT B ATTERY EMOVAL Perform this procedure to remove the ELT battery. Take care when removing the ELT from its mounting. Removed improperly, the ELT can trigger a false emergency signal. Possible fines may be imposed if there is a false activation of an ELT.
Page 461 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Figure 25-28 ELT Battery Replacement Carefully lift the cover (battery pack) away from the ELT and unplug the flex-cable connected to the battery pack. Do not pull on the flexible portion of the cable – use the rigid section of the flex circuit at the connector as a handle.
Page 462 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Examine batteries and battery case contacts for any dirt or corrosion. Clean the contacts as necessary using Electrical Contact cleaner and a stiff brush. The battery case contacts are nickel and gold plated spring steel. Abrasive material will remove this plating.
Page 463 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT B ATTERY NSTALLATION Perform this procedure to install the batteries into an ELT. This procedure is done out of the airplane. Use only an Artex part number 452-6499 battery. Replacement batteries are obtained in kits containing all parts and labels that must be replaced with the battery.
Page 464 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT I NSTALLATION Perform this procedure to install the Emergency Locator Transmitter. Take care when removing the ELT from its mounting. Removed improperly, the ELT can trigger a false emergency signal. Possible fines may be imposed if there is a false activation of an ELT.
Page 465 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOTE ONTROL WITCH EMOVAL Perform this procedure to remove the ELT remote control switch. Position aircraft master switch to OFF. Verify remote switch ELT activity LED is OFF. Remove four (4) 4-40 machine screws securing the remote switch to the avionics panel.
Page 466 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOTE WITCH ATTERY EMOVAL AND NSTALLATION Perform this procedure to remove and install the ELT remote switch battery cell. Referring to Figure 25-31, remove four (4) retaining screws from the remote switch body to access the battery compartment.
Page 467 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Gently route black and red wire leads from the plastic cell holder away from the leads of the rocker switch as necessary. Position the ground wire (black) along the side of the plastic cell holder and away from the screw boss.
Page 468 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT R EMOTE ONTROL WITCH NSTALLATION Perform this procedure to install the ELT remote control switch. Position aircraft master switch to OFF. Locate and connect switch extension cable connector (P76) and ground connector (P79). Refer to Figure 25-30 for the location both connectors.
Page 469 Perform this procedure to perform an operational check and inspection of the ELT. Procedures to follow provide inspection and maintenance required to comply with 100 hour and annual ELT inspection requirements, specified in Liberty maintenance manual Chapter 05 – Time Limits/Maintenance Checks/Inspection Intervals.
Page 470 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Figure 25-32 406/121.5 ELT Antenna Inspection Inspect the avionics panel mounted ELT remote switch face for condition, evidence or damage or other factors affecting proper ELT operation. If a 100 hour inspection is being performed proceed with step 19 else proceed with step 11 to complete an annual inspection.
Page 471 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Perform the ELT Remote Control Switch Installation procedure shown on page 54 of this chapter. Verify current ELT registration. As required, prior to returning the airplane to service, perform the ELT Registration procedure shown on page 65 of this chapter.
Page 472 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE WITCH CHECK Perform this procedure to check the G-switch. The G-switch is a simple electromechanical switch intended to operate when an abrupt change of direction occurs. Test the switch by applying a force of 3 G’s (Gravity) or more in a rearward direction.
Page 473 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE Verify ELT Status LED is OFF. Remove shorting plug from remote control switch interface connector. Perform the ELT Installation procedure on page 50 of this chapter. This completes the G-Switch check procedure. 25-60 P/N 135A-970-100...
Page 474: Elt 121.5 Mhz Transmitter Test
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT 121.5 MH RANSMITTER Perform this procedure to test the 121.5MHz transmitter. Start and complete the following test between the top of the hour and five (5) minutes past the hour. This is the only time during each hour to perform this test without alerting monitoring agencies.
Page 475 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT 406 MH RANSMITTER Perform this procedure to test the ELT 406 MHz transmitter. The following test requires use of a suitable test set capable of reading and decoding 406 MHz ELT transmitted signal messages. Artex test set part number 453-1000 or...
Page 476 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE After the third sweep, on the ELT remote switch located on the avionics panel, press ARM Verify the alarm and LED gives only one flash. If more than one LED flash is seen record the number of flashes and refer to troubleshooting guide section for corrective action.
Page 477 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ESET FROM THE EMOTE WITCH Perform this procedure to reset the ELT from the remote switch. To “RESET” the ELT, locate the remote switch located in the avionics panel below the transponder. See Figure 25-37.
Page 478: Reset Elt From Local Controls
EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT F ESET OCAL ONTROLS Perform this procedure to reset the ELT from the local controls. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 479 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE ELT Registration Section 60-15 All ELTs operating on 406 MHz must be registered. In the United States, the National Oceanic and Atmospheric Administration (NOAA) is the agency that administrates beacon registration. Upon registration, NOAA will issue a “Proof of Registration”...
Page 480 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE 406/121.5 MHz ELT Troubleshooting Guide Section 60-16 Use Table 25-7 as a guide to troubleshoot issues with the ELT. SYMPTOM LIKELY CAUSE ACTION Indicates system is operational 1 Flash after and that no error conditions were...
Page 481 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE SYMPTOM LIKELY CAUSE ACTION installed correctly. for correct orientation Buzzer failed Replace buzzer Buzzer fails to sound on ELT Check ELT tray connections to the Buzzer disconnected activation buzzer. Connect as required. ELT battery leaking...
Page 482 EQUIPMENT AND FURNISHINGS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 25-60 P/N 135A-970-100 Page 68 of 68 REVISION D...
Page 483 FLIGHT CONTROLS XL-2 AIRPLANE CHAPTER 27 FLIGHT CONTROLS Chapter 27 P/N 135A-970-100 REVISION E Page 1 of 122...
Page 484 XL-2 AIRPLANE Copyright © 2011 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 485 FLIGHT CONTROLS XL-2 AIRPLANE Table of Contents 27-00 ECTION ENERAL 00-01 ECTION ENGTHS 27-10 ECTION ILERON 10-01 ECTION ILERON ROCEDURES ILERON EMOVAL ILERON NSTALLATION ILERON RANK EMOVAL ILERON RANK NSTALLATION ILERON UTBOARD USHROD EMOVAL ILERON UTBOARD USHROD NSTALLATION NBOARD USHROD...
Page 486 FLIGHT CONTROLS XL-2 AIRPLANE 27-30 ECTION TABILATOR AND 30-01 ECTION TABILATOR YSTEM ROCEDURES TABILATOR EMOVAL TABILATOR NSTALLATION FUSELAGE ITCH ONTROL DLER PLATE EMOVAL FUSELAGE ITCH ONTROL DLER PLATE NSTALLATION ERVO EMOVAL ERVO NSTALLATION ITCH CTUATOR EMOVAL ITCH CTUATOR NSTALLATION 30-02...
Page 487 FLIGHT CONTROLS XL-2 AIRPLANE Section 27-00 General The flight controls of the airplane include conventional aileron, rudder and stabilator with anti-servo/trim tab. All flight controls are operated by pushrods, with dual controls operating the aileron and the stabilator, and dual rudder pedals operating the rudder. The left (pilot) and right (co-pilot) rudder pedals are individually adjustable to accommodate different pilot heights and leg lengths.
Page 488 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-1 Torque Tube Distance 27-00 P/N 135A-970-100 Page 6 of 122 REVISION ~...
Page 489 FLIGHT CONTROLS XL-2 AIRPLANE Section 27-10 Aileron The airplane aileron is of conventional aluminum construction and is hinged to the lower wing surface by conventional piano hinges. The port aileron is equipped with a ground adjustable control surface trim tab, located at the outboard rear of the aileron.
Page 490 FLIGHT CONTROLS XL-2 AIRPLANE Access to bearings in the chassis center section is gained by removing the fuselage belly panel (see Chapter 53 - Fuselage). Access to both the fuselage and wing components of the aileron quick-connect fittings is gained by removal of the wing(s) (see Chapter 57 - Wings).
Page 491: Aileron Removal
Temporarily mark (using masking tape) on the aileron and on the aileron hinge, alignment marks such that when installing the aileron, the aileron will be in the same position, see Figure 27-3. If installing a different aileron, contact Liberty Aerospace, Inc. Customer Service. Figure 27-3 Alignment Marks Using Masking Tape Remove split pin (1), nut (2), washer (3) and bolt (4) that attach pushrod to inboard end of aileron (nearest to flap) to disconnect pushrod.
Page 492 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-4 Screws Removal on Aileron Hinge While supporting pushrod, remove aileron. ILERONS ARE MASS BALANCED CONTROL SURFACES F MASS BALANCE WEIGHTS ARE REMOVED THEY MUST BE MARKED FOR RE INSTALLATION IN PROPER POSITION REPAIRS MADE TO AILERONS...
Page 493: Aileron Installation
FLIGHT CONTROLS XL-2 AIRPLANE ILERON NSTALLATION Perform this procedure to install the aileron. ILERONS ARE MASS BALANCED CONTROL SURFACES F MASS BALANCE WEIGHTS ARE REMOVED THEY MUST BE MARKED FOR RE INSTALLATION IN PROPER POSITION REPAIRS MADE TO AILERONS INCLUDING REPAINTING...
Page 494 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-5 Details of the Pushrod Assembly Verify inner bearing race is clamped, and outer race is free to rotate through its full range. Check clearances between the top of the aileron skin and the wing trailing edge skin (T/E) as follows per Table 27-2 and Figure 27-6.
Page 495 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-6 Details for the Measurement of the Aileron Check clearance of 0.050” (minimum) between aileron mass balance arm and internal surface of wing skin, with aileron in the down position (2 places port/2 places starboard).
Page 496 FLIGHT CONTROLS XL-2 AIRPLANE Remove aileron. Clamp wing trailing edge uniformly and continuously (see Figure 27-8) Figure 27-8 Opening “C” Channel of Wing Aileron Closeout. When bending trailing edge up, do not exceed 0.2" over a distance of 2.0" measured along wing chord.
Page 497: Aileron Wing Bell-Crank Removal
FLIGHT CONTROLS XL-2 AIRPLANE ILERON RANK EMOVAL Perform this procedure to remove the bell-crank. Refer to Figure 27-9 during this procedure. Figure 27-9 Aileron Wing Bell-crank Assembly Remove two access panels on lower wing surface to gain access to bell- crank.
Page 498: Aileron Wing Bell-Crank Installation
FLIGHT CONTROLS XL-2 AIRPLANE ILERON RANK NSTALLATION Perform this procedure to install the bell crank. Refer to Figure 27-10 during this procedure. Figure 27-10 Aileron Wing Bell-crank Assembly Using bolt (10), temporarily position bell-crank (6) and bushings (11). To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut..
Page 499 FLIGHT CONTROLS XL-2 AIRPLANE To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Reconnect outboard aileron pushrod (5) using bolt (4), washer (3) and castellated nut (2). Torque to a value of at least 50 in-lbs. Continue to torque to nearest castellated slot for split pin.
Page 500: Aileron Outboard Wing Pushrod Removal
FLIGHT CONTROLS XL-2 AIRPLANE ILERON UTBOARD USHROD EMOVAL Perform this procedure to remove the outboard wing pushrod. Remove two access panels on lower wing surface to gain access to bell- crank. Fully extend wing flap. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut.
Page 501: Aileron Outboard Wing Pushrod Installation
FLIGHT CONTROLS XL-2 AIRPLANE ILERON UTBOARD USHROD NSTALLATION Perform this procedure to install the aileron outboard wing pushrod. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. If installing a different pushrod than the one removed in the removal procedure, adjust the replacement pushrod to the length shown in Table 27-1.
Page 502: Inboard Wing Pushrod Removal
FLIGHT CONTROLS XL-2 AIRPLANE NBOARD USHROD EMOVAL Perform this procedure to remove the inboard wing pushrod. Wing(s) must be removed from airplane (See Chapter 57 - Wings). Remove 2 access panels on lower wing surface to gain access to bell- crank.
Page 503 FLIGHT CONTROLS XL-2 AIRPLANE NBOARD USHROD NSTALLATION Perform this procedure to install the inboard wing pushrod. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. If installing a different pushrod than the one removed in the removal procedure, check the length of the replacement pushrod against the length shown in Table 27-1.
Page 504: Wing-Mounted Quick-Disconnect Device Removal
FLIGHT CONTROLS XL-2 AIRPLANE OUNTED UICK ISCONNECT EVICE EMOVAL Perform this procedure to remove the wing mounted quick-disconnects. Refer to Figure 27-14. Wing(s) must be removed from airplane (See Chapter 57 - Wings). Figure 27-14 Wing Root Assembly To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut.
Page 505: Wing-Mounted Quick-Disconnect Device Installation
FLIGHT CONTROLS XL-2 AIRPLANE OUNTED UICK ISCONNECT EVICE NSTALLATION Perform this procedure to install the wing mounted quick-disconnects. Refer to Figure 27-15. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Figure 27-15 Wing Root Assembly Install quick-disconnect device (2).
Page 506 FLIGHT CONTROLS XL-2 AIRPLANE between the two mating surfaces must only be between 0.000” (minimum) and 0.006” (maximum). Verify inner bearing race is clamped, and outer race is free to rotate through its full range. Check for correct operation and freedom of movement. When alignment is correct, pushrod will freely rotate approximately 1/10 of a turn.
Page 507: Inboard Quick-Disconnect Device Removal
FLIGHT CONTROLS XL-2 AIRPLANE NBOARD UICK ISCONNECT EVICE EMOVAL Perform this procedure to remove the inboard quick-disconnect device. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Remove belly panel (see Chapter 53 - Fuselage).
Page 508: Inboard Quick-Disconnect Device Installation
FLIGHT CONTROLS XL-2 AIRPLANE NBOARD UICK ISCONNECT EVICE NSTALLATION Perform this procedure to install the inboard quick-disconnect device. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Figure 27-17 Aileron Inboard Quick-disconnect Device Install quick-disconnect device (7) using two bolts, four washers, and two nuts (6).
Page 509: Inboard Aileron Push Rod Removal
FLIGHT CONTROLS XL-2 AIRPLANE NBOARD ILERON EMOVAL Perform this procedure to remove the inboard aileron push rod. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Remove belly panel (see Chapter 53 - Fuselage).
Page 510: Inboard Aileron Pushrod Installation
FLIGHT CONTROLS XL-2 AIRPLANE NBOARD ILERON USHROD NSTALLATION Perform this procedure to install the inboard aileron pushrod. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Figure 27-19 Aileron Inboard Pushrod to Torque Tube...
Page 511 FLIGHT CONTROLS XL-2 AIRPLANE When installed correctly, the components should mate together without slippage between parts. Verify rigging in accordance with Section 27-90 Rigging Procedures on page 103 this chapter. Install belly panel (see Chapter 53 – Fuselage). 27-10 P/N 135A-970-100...
Page 512: Aileron Torque Tube Removal
FLIGHT CONTROLS XL-2 AIRPLANE ILERON ORQUE EMOVAL Perform this procedure to remove the aileron torque tube To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Remove belly panel (see Chapter 53 – Fuselage).
Page 513 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-21 Aileron Torque Tube (Front) Pull torque tube aft, retaining bearings (4), noting their positions and orientation on torque tube. Work aileron torque tube around, down, and out through belly opening. 27-10 P/N 135A-970-100 REVISION D...
Page 514: Aileron Torque Tube Installation
FLIGHT CONTROLS XL-2 AIRPLANE ILERON ORQUE NSTALLATION Perform this procedure to install the aileron torque tube. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Work aileron torque tube around, up, and into position through belly opening.
Page 515 FLIGHT CONTROLS XL-2 AIRPLANE Aileron Inspection Section 10-02 Inspect the following items on the aileron for abnormalities: • Inspect aileron skin for dents, scratches, malformations, bubbled paint, and foreign object debris. • Inspect for “smoking rivets”. “Smoking Rivets” – Term used to describe a loose or working rivet whose vibration causes a black streak trailing aft.
Page 516 FLIGHT CONTROLS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK. 27-10 P/N 135A-970-100 Page 34 of 122 REVISION D...
Page 517 FLIGHT CONTROLS XL-2 AIRPLANE Section 27-20 Rudder The airplane rudder is of conventional aluminum construction. It is attached to the starboard side of the fuselage vertical fin by a full-length piano hinge. A fixed ground-adjustable trim tab is attached to the trailing edge of the rudder...
Page 518 FLIGHT CONTROLS XL-2 AIRPLANE Port side (pilot) and starboard (copilot) rudder pedal assemblies are connected to a transverse torque tube located behind the instrument panel. Movement of the left/right pedals rotates the torque tube. This rotation deflects the rudder via a series of bell-cranks, idler bearings, and pushrods which pass through the cockpit center console and aft fuselage.
Page 519 Removal and replacement of the forward and intermediate rudder pushrods is not anticipated during routine maintenance. In the event that forward and forward and intermediate rudder need to be removed from the airplane, contact Liberty Customer Support for the recommended procedure.
Page 520: Rudder Removal
FLIGHT CONTROLS XL-2 AIRPLANE UDDER EMOVAL Perform this procedure to remove the rudder. Two persons are required for this procedure. Rudder hinge remains with rudder. Remove 13 washer-head screws securing rudder hinge to right side of vertical fin. See Figure 27-25.
Page 521 FLIGHT CONTROLS XL-2 AIRPLANE Remove split pin (1) and discard. Remove the nut (1), washers (3) and bolt (4) securing pushrod end bearing to rudder drive brackets, noting placement of washers. Figure 27-26 Rudder Pushrod Aft Connection Remove rudder. Do not operate rudder pedals while rudder is removed. Operating rudder pedals while rudder is removed may damage the composite vertical stabilizer-rudder closeout.
Page 522: Rudder Installation
FLIGHT CONTROLS XL-2 AIRPLANE UDDER NSTALLATION Perform this procedure to install the rudder. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Two persons are required for this procedure. If installing a different pushrod than the one removed in the removal procedure, adjust the replacement pushrod to the length shown in Table 27-1.
Page 523 FLIGHT CONTROLS XL-2 AIRPLANE UDDER FUSELAGE DLER PLATE EMOVAL Perform this procedure to remove the rudder mid-fuselage idler-plate. Before starting this procedure, the tail of airplane requires support. Failure to support tail of airplane may cause damage to tail section while accessing any area aft of passenger compartment.
Page 524 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-28 Disconnecting Fwd. Rudder Pushrod Refer to Figure 27-28. Remove split pin (1) and discard. Remove the nut (2), washers (3 and 4), and bolt (5) from idler plate (6) and separate intermediate rudder pushrod from idler-plate.
Page 525: Rudder Mid-Fuselage Idler-Plate Installation
FLIGHT CONTROLS XL-2 AIRPLANE UDDER FUSELAGE DLER PLATE NSTALLATION Perform this procedure to install the rudder mid-fuselage idler-plate. Before starting this procedure, the tail of airplane requires support. Failure to support the tail of airplane may cause damage to tail section while accessing any area aft of passenger compartment.
Page 526 FLIGHT CONTROLS XL-2 AIRPLANE See Figure 27-31. Attach forward rudder pushrod to rudder idler-plate using bolt (6), washers (3 and 4), and castellated nut (2). Torque the nut in accordance with Chapter 53 - Fuselage. Insert a new split pin (8).
Page 527: Forward Rudder Bell-Crank Removal
FLIGHT CONTROLS XL-2 AIRPLANE ORWARD UDDER CRANK EMOVAL Perform this procedure to remove the forward rudder bell-crank. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Remove belly panel (See Chapter 53 - Fuselage).
Page 528 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-33 Exploded View of the Input Pushrod to Forward Bell-crank Remove split pin (1) and discard. Remove the nut (2), washer (3), and bolt (4) that fasten forward rudder bell-crank to space frame and remove bell- crank.
Page 529 FLIGHT CONTROLS XL-2 AIRPLANE ORWARD UDDER CRANK NSTALLATION Perform this procedure to install the forward rudder bell-crank. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Install forward rudder bell-crank using bolt (4), washer (3), and castellated nut (2).
Page 530 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-36 Exploded View of the Input Pushrod to Forward Bell-crank Install forward pushrod to forward rudder bell-crank using bolt (5), spacer (4), washer (3), and nut (2). Torque the nut in accordance with Chapter 20 - Standard Practices.
Page 531: Rudder Input Pushrod Removal
FLIGHT CONTROLS XL-2 AIRPLANE UDDER NPUT USHROD EMOVAL Perform this procedure to remove the rudder input pushrod. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Remove belly panel (see Chapter 53 - Fuselage).
Page 532: Rudder Input Pushrod Installation
FLIGHT CONTROLS XL-2 AIRPLANE UDDER NPUT USHROD NSTALLATION Perform this procedure to install the rudder input pushrod. Refer to Figure 27- 39during this procedure. Figure 27-39 Exploded View of the Rudder Input Pushrod To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut.
Page 533 FLIGHT CONTROLS XL-2 AIRPLANE Check for correct operation and freedom of movement. When alignment is correct, pushrod will freely rotate approximately 1/10 of a turn. Check rudder pedal assembly for normal unrestricted operation. Verify rigging in accordance with Section 27-90 Rigging Procedures on page 103 this chapter.
Page 534: Rudder Pedal Assembly Removal
Failure to disconnect batteries may cause damage to airplane electrical circuitry. 1. Cover forward windscreen internally to protect from scratching. Liberty recommends using Shrink-Wrap plastic. 2. Two people are required for the removal procedure.
Page 535 FLIGHT CONTROLS XL-2 AIRPLANE To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Disconnect rudder input pushrod from rudder pedal assembly transverse torque tube in accordance with the Rudder Input Pushrod Removal procedure on page 49 of this chapter.
Page 536 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-41 Brake Pedal Assembly Hydraulic Line Fittings Lift rudder pedal assembly straight out and away from fuselage and out of airplane. 27-20 P/N 135A-970-100 Page 54 of 122 REVISION E...
Page 537: Rudder Pedal Assembly Installation
Failure to disconnect batteries may cause damage to airplane electrical circuitry. 1. Cover forward windscreen internally to protect from scratching. Liberty recommends using Shrink-Wrap plastic. 2. Two people are required for installation procedure.
Page 538 FLIGHT CONTROLS XL-2 AIRPLANE Check rudder pedal assembly moves freely. Upper fittings on starboard rudder pedals (1 and 2) are compression fittings. Compression sleeves must be replaced, necessitating removal of portion of tubing end. If resultant tubing length prohibits proper connection, tubing must be replaced.
Page 539 FLIGHT CONTROLS XL-2 AIRPLANE XTENDING THE LOSEOUT OLE FOR THE UDDER If during the inspection, or if binding is detected when using the rudder, perform this procedure to extend the closeout hole in the fuselage. ANDING OR GRINDING THE FUSELAGE...
Page 540 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-43 Showing Area of Fuselage Figure 27-44 Before and After Extending the Pass-thru Hole Finish with a diamond tip barrel grinder. Check that the new boundary of the pass through hole, does not have any delaminations or sharp edges.
Page 541 Inspect the control surface and control circuit for damage that may be hidden that resulted from the impact. Contact Liberty Aerospace, Inc. for inspection details. 27-20 P/N 135A-970-100...
Page 542 FLIGHT CONTROLS XL-2 AIRPLANE Troubleshooting Section 20-03 Table 27-4 contains information to aid in troubleshooting issues with the rudder system. Complaint Possible Cause Remedy Dirty, “dry,” or defective rod Lubricate with Corrosion X or end bearings in rudder linkage replace as necessary...
Page 543 FLIGHT CONTROLS XL-2 AIRPLANE Section 27-30 Stabilator and Tab The Liberty XL-2 airplane uses an all-flying stabilator with an anti-servo/trim tab on the trailing edge. Figure 27-46 shows the various parts in the stabilator system. Figure 27-46 Horizontal Stabilizer Control Circuit Geometry The tab has the following functions: •...
Page 544 Removal and replacement of the forward and rear pitch control pushrods is not anticipated during routine maintenance. In the event that forward and rear pitch control pushrods need to be removed from the airplane, contact Liberty Customer Support for the recommended procedure.
Page 545 FLIGHT CONTROLS XL-2 AIRPLANE TABILATOR EMOVAL Perform this procedure to remove the stabilator. Figure 27-47 Stabilator Assembly Take precautions to prevent damage to the surface airfoil when removing bolt assembly. Remove and discard split pin from castellated nut on stabilator attach bolt.
Page 546 FLIGHT CONTROLS XL-2 AIRPLANE TABILATOR NSTALLATION Perform this procedure to install the stabilator. Prior to installation, inspect the torque tube for any type of corrosion or oxidation. If the torque tube does not have a primer coat refer to Chapter 55 –...
Page 547 XL-2 AIRPLANE No lateral, fore/aft, or up/down movement should be detected. If any lateral movement greater than .006” is detected, contact Liberty Aerospace Customer Support for additional instructions. If any fore/aft or up/down movement is detected, replace stabilator bearing(s) in accordance with procedures in Chapter 55 - Stabilizers.
Page 548 FLIGHT CONTROLS XL-2 AIRPLANE FUSELAGE ITCH ONTROL DLER PLATE EMOVAL Perform this procedure to remove the mid-fuselage pitch control idler plate. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Figure 27-49 Mid-fuselage Pitch Control Idler-plate Location Remove belly panel (see Chapter 53 - Fuselage).
Page 549 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-50 Rear Pitch Control Pushrod to Mid-fuselage Pitch Control Idler-plate Refer to Figure 27-51. Remove the split pin (6) and discard. Remove the nut (7), washers (8 & 9), and spacer (10). Note the locations of washers and spacer.
Page 550 FLIGHT CONTROLS XL-2 AIRPLANE Check the center space remains on bolt and temporarily re-install the bolt into space frame connector and loose-fit nut for temporarily support to the rudder pushrods and idler plate. Figure 27-52 Mid-fuselage Pitch Control Idler-plate Removal and Installation...
Page 551 FLIGHT CONTROLS XL-2 AIRPLANE FUSELAGE ITCH ONTROL DLER PLATE NSTALLATION Perform this procedure to install the mid-fuselage pitch control idler plate. To ensure that rigging is not disturbed, do not alter or adjust pushrod end adjustment jam nut. Refer to Figure 27-52. Remove nut (14) that was placed on bolt (17) to temporarily support rudder pushrods and idler plate.
Page 552 FLIGHT CONTROLS XL-2 AIRPLANE ERVO EMOVAL Perform this procedure to remove the anti-servo/trim tab. Anti-servo/trim tab hinge is located on stabilator top surface. Figure 27-53 Stabilator and Anti-servo/Trim Tab Remove Stabilator from airplane in accordance with the Stabilator Removal procedure on page 63 of this chapter. Place on workbench in inverted position.
Page 553 FLIGHT CONTROLS XL-2 AIRPLANE ERVO NSTALLATION Perform this procedure to install the anti-servo/trim tab. Install anti-servo/trim tab onto stabilator. Take care to position hinge of tab between outer skin of stabilator and underlying structure. Install five screws (5) that fasten anti-servo/trim tab hinge to stabilator.
Page 554 FLIGHT CONTROLS XL-2 AIRPLANE ITCH CTUATOR EMOVAL Perform this procedure to remove the pitch trim actuator. Refer to Figure 27-55 during this procedure. Figure 27-55 Pitch Trim Actuator and Linkage Place the BAT master switch to ON. Position the pitch trim to full nose-down position.
Page 555 FLIGHT CONTROLS XL-2 AIRPLANE ITCH CTUATOR NSTALLATION Perform this procedure to install the pitch trim actuator. Clean the hardware used to secure motor end of trim actuator to airframe. Temporarily install trim actuator assembly in position. Check the stabilator. Make sure that it is locked in neutral position.
Page 556 FLIGHT CONTROLS XL-2 AIRPLANE Wet assemble bolt securing motor end of trim actuator to airframe bracket. Verify position of bushings and rod. See Figure 27-57. Figure 27-57 Trim Actuator to Airframe Installation Re-install bolt securing bearing end of trim actuator to trim linkage and hand torque bolt, replace split pin.
Page 557 Stabilizers. • Check the tab to horizontal stabilizer hinge pin and attachment, there shall be no visible free play If either of these inspections fails, contact Liberty Aerospace, Inc. for further instruction. Troubleshooting Section 30-03 This section contains the troubleshooting information.
Page 558 FLIGHT CONTROLS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 27-30 P/N 135A-970-100 Page 76 of 122 REVISION D...
Page 559 FLIGHT CONTROLS XL-2 AIRPLANE Section 27-40 Control Yoke The control yoke provides pilot, and/or copilot, input to the ailerons for roll control, and stabilators for pitch control. The yoke assembly consists of a weldment providing physical attachments for the forward pitch control pushrod and aileron torque tube.
Page 560 FLIGHT CONTROLS XL-2 AIRPLANE ONTROL EMOVAL Perform this procedure to remove the yoke boot. Refer to Figure 27-58 during this procedure. Figure 27-58 Control Yoke Boot Remove eight bolts fastening control yoke boot to fuselage. Carefully cut the two tie wraps that secure the boot to the control yoke.
Page 561 FLIGHT CONTROLS XL-2 AIRPLANE ONTROL NSTALLATION Perform this procedure to install the control yoke boot. Refer to Figure 27-58 during this procedure. Maneuver control boot over and onto control stick. Install eight bolts to fasten control yoke boot to fuselage.
Page 562 FLIGHT CONTROLS XL-2 AIRPLANE TARBOARD PILOT ONTROL TICK EMOVAL Perform this procedure to remove the starboard (co-pilot) control stick. Refer to Figure 27-60 during this procedure. If control stick is to remain removed from airplane during flight, install the ground cable, bolt (4), washer (3), nut (2), and new split pin.
Page 563 FLIGHT CONTROLS XL-2 AIRPLANE TARBOARD PILOT ONTROL TICK NSTALLATION Perform this procedure to install the starboard (co-pilot) control stick. Refer to Figure 27-60 during this procedure. Maneuver control stick into position. Feed PTT cable through weldment. Install control stick using bolt (4), washer (3), ground cable, and castellated nut (2).
Page 564 FLIGHT CONTROLS XL-2 AIRPLANE WITCH EMOVAL Perform this procedure to remove the push-to-talk switch assembly. This procedure can be used for either the pilot’s or the copilot’s push-to-talk switch assembly. Refer to Figure 27-61 for details of this procedure. Figure 27-61 Details of the Pilot’s/Copilot’s Push-To-Talk Switch Assembly...
Page 565 FLIGHT CONTROLS XL-2 AIRPLANE WITCH NSTALLATION Perform this procedure to install the push-to-talk switch assembly. This procedure can be used for either the pilot’s or the copilot’s push-to-talk switch assembly. Refer to Figure 27-61 for details of this procedure. Remove belly panel (see Chapter 53 - Fuselage).
Page 566 FLIGHT CONTROLS XL-2 AIRPLANE ONTROL SSEMBLY EMOVAL Perform this procedure to remove the control yoke assembly. Figure 27-62 Control Yoke Removal and Installation Remove starboard control stick in accordance with the Starboard (Co-pilot) Control Stick Removal procedure on page 80 of this manual.
Page 567 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-63 Forward Pitch Control Pushrod to Yoke Assembly Remove split pin (1) and discard. Remove the nut (2), washer (3), and bolt (4) connecting aileron torque tube to control yoke assembly and separate control yoke from torque tube.
Page 568 FLIGHT CONTROLS XL-2 AIRPLANE ONTROL SSEMBLY NSTALLATION Perform this procedure to install the control yoke assembly. Extreme care must be taken while maneuvering yoke assembly into airplane so as not to damage instrument panel, fuselage, or control yoke assembly. Carefully maneuver yoke assembly up into airplane and through fuselage...
Page 569 FLIGHT CONTROLS XL-2 AIRPLANE Section 27-50 Flaps The airplanes single-slotted wing flaps are of conventional aluminum construction. Each flap attaches to the wing by three hinges set approximately six inches below the wing lower surface. Figure 27-64 Flaps Control Circuit Geometry A single electrical flap actuator operating a flap drive cross-tube between the port and starboard flap drives the flaps.
Page 570 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-65 Flap Drive Linear Actuator Assembly Flap System Procedures Section 50-01 This section contains the procedures for the flap systems. 27-60 P/N 135A-970-100 Page 88 of 122 REVISION D...
Page 571 FLIGHT CONTROLS XL-2 AIRPLANE EMOVAL Fully extend flap. Support flap at each end. Remove split pins and discard. Remove the nuts, and washers from three hinge bolts. Remove hinge bolts, and spacers, noting their locations. It is necessary to move aileron to full up or neutral position to allow flap to be removed.
Page 572 FLIGHT CONTROLS XL-2 AIRPLANE NSTALLATION With power applied to electrical system hold flap switch in DOWN position until flap indicator shows full down and flap actuator stops moving to check that the flap drive tube is fully extended. Support flap at both ends. Align drive spigot in flap root rib with bearing in flap drive cross tube and slide flap inboard to engage spigot.
Page 573 FLIGHT CONTROLS XL-2 AIRPLANE Clearance Description 1653-lbs 1750-lbs Top of flap skin to wing T/E 0.050” 0.070” Flap 0º and in transition (A) Flap Rivet tails to wing T/E 0.080” 0.100” Flap 0º and in transition (B) Rivet heads (Rib 0 thru Rib 7) and Flap leading edge 0.050”...
Page 574 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-69 Opening “C” Channel of Wing-Flap Closeout When bending trailing edge up, do not exceed 0.2" over a distance of 2" measured along wing chord. Bend radius 'R' must be gradual, continuous and not leave tool marks, significant surface impression, or any surface cracks.
Page 575 FLIGHT CONTROLS XL-2 AIRPLANE CTUATOR EMOVAL Perform this procedure to remove the flap actuator. See Figure 27-70. Figure 27-70 Flap Actuator Fully extend flap. Remove belly panel (see Chapter 53 - Fuselage). Disconnect flap actuator electrical connector (1). Remove bolt securing bearing end of actuator (2) to flap cross tube.
Page 576 FLIGHT CONTROLS XL-2 AIRPLANE CTUATOR NSTALLATION Perform this procedure to install the flap actuator. See Figure 27-70 Position flap actuator to fully extended position by applying 12 Vdc to pins 1 and 2 of electrical connector; reversing polarity will reverse motion.
Page 577 ENSOR EMOVAL Perform this procedure to remove the flap position sensor. For adjustment of flap sensor indicator refer to 135A-911-050 Liberty XL-2 Rigging Procedure for appropriate steps. Remove belly panel (see Chapter 53 - Fuselage). Disconnect electrical connector (1) at flap position sensor.
Page 578 FLIGHT CONTROLS XL-2 AIRPLANE OSITION ENSOR NSTALLATION Perform this procedure to install the flap position sensor. Install sensor and install bolts securing sensor to airframe (2). Connect electrical connector to flap position sensor (1). Install belly panel. 27-60 P/N 135A-970-100...
Page 579 Checks/Inspection Intervals of this manual include the scheduled maintenance procedures for the flaps. Those inspection and maintenance procedures are mandatory to support the continued airworthiness of the Liberty XL-2. In addition, the following inspections are recommended when performing flap inspection: With the wings installed on the airplane, check the flap for lateral movement.
Page 580 FLIGHT CONTROLS XL-2 AIRPLANE Any binding may cause lateral bending of flap hinges under load as stated in (CSB-07- 002). With the flap pulled fully towards the fuselage, check the clearance of the flap to the fuselage. This clearance must be a minimum of 0.20 in (0.30 in maximum) between flap and fuselage.
Page 581 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-76 Flap Shim 27-60 P/N 135A-970-100 REVISION D Page 99 of 122...
Page 582 Flap Repair Section 50-02 At the time of this printing, Liberty Aerospace has not 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 airplane before that time, contact Customer service at Liberty Aerospace for assistance.
Page 583 Bent Flap Drive Tube If this deformation is suspected, welded areas highlighted below should be inspected for any cracks by Magnetic Particle Inspection (MPI) or by qualified technician and the result should be reported to Liberty Customer Support. Figure 27-79 Cracks Inspection Area...
Page 584 FLIGHT CONTROLS XL-2 AIRPLANE Flap Troubleshooting Section 50-04 Table 27-8 will aid in troubleshooting issues with the flaps. Complaint Possible Cause Remedy Defective flap circuit breaker Replace Defective flap switch Replace Flap inoperative Defective flap actuator Replace Defective wiring Repair...
Page 585 The aircraft must not be subject to air movements or wind. The SmartTool TM Digital Inclinometer & bevel protractor referred to in this section is available for purchase from Liberty Aerospace, Inc. or through the internet Always zero out the SmartTool TM Digital Inclinometer by the inbuilt calibrating procedure prior to use, so that when moving from location to location &...
Page 586 FLIGHT CONTROLS XL-2 AIRPLANE & ERIFICATION OF FLYING SURFACES RELATIVE MOVEMENT RESPONSE Perform the following to verify that control surfaces move and respond correctly to inputs from the cockpit. Start with the Ailerons and Horizontal Stabilizers then move to the rudder and finally with the power controlled flaps and trim tabs.
Page 587 FLIGHT CONTROLS XL-2 AIRPLANE As the flap deploys, the flap spigot must slide freely within the bearing of the flap drive cross bar assembly. If the flap spigot does not slide within the bearing smoothly, clean the flap drive spigot and oil spigot and bearing using MIL-PRF-32033D.
Page 588 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-80 Tail Section Measurements Run the trim tab fully in both directions to verify proper movement of control surface. If the following conditions are not met then an investigation into switch orientation and wiring must be initiated.
Page 589 A&P mechanic should verify the new pushrod distance between the two end fittings and that it is consistent with the push rod being removed. If this is not the case, contact Liberty Aerospace, Inc. Customer Service. Place the Master Power Switch for the Battery to ON. All other switches are OFF.
Page 590 Asymmetry between port and starboard measurement must not exceed 1°. If the measurement of the asymmetry is within 1°, go to step 13. If the measurements violate the asymmetry specification, contact Liberty Aerospace, Inc. Customer Service before making any adjustments. If...
Page 591 Liberty Aerospace, Inc. Customer Service. This procedure calls for the use of rigging blocks, part number 135A-02-511. These rigging blocks are available. Contact the Customer Service department of Liberty Aerospace, Inc. Remove the belly panel (see Chapter 53 – Fuselage).
Page 592 FLIGHT CONTROLS XL-2 AIRPLANE Verify using feeler gages that the parallel gap between the mating faces of the aileron quick connect channel and the port aileron quick connect bearing assembly falls between 0.001 inches and 0.006 inches. When using the filler gage to measure the gap between the mating faces of the quick disconnect, the gage must be fully inserted such that it is making contact along the entire surface area between the disconnects.
Page 593 FLIGHT CONTROLS XL-2 AIRPLANE If the gap is greater than 0.006in, reduce the gap by bringing the two assemblies closer together by adjusting the aileron quick connect assembly mounted to the wing. Adjusting the aileron quick connect assembly requires removing the wing from the airplane. Refer to Chapter 57 – Wings.
Page 594 FLIGHT CONTROLS XL-2 AIRPLANE Record all angles as an absolute Port Starboard value (disregarding any + or - sign) Aileron Aileron Inclinometer reading at neutral Inclinometer reading at aileron fully up Inclinometer reading at aileron fully down Aileron Deflection Up (Add Lines 1 and 2) 24.0°±...
Page 595 FLIGHT CONTROLS XL-2 AIRPLANE If the range for the starboard aileron is not within the range of 43.0°± 1.0°, adjust the starboard aileron deflection range by adjusting the starboard aileron push rod ladder. To reduce the range, lengthen the push rod. To increase the range, shorten the push rod.
Page 596 FLIGHT CONTROLS XL-2 AIRPLANE Adjust the port aileron to 0.5° of the port wing tip, by adjusting the port aileron pushrod. Adjust starboard aileron as necessary by adjusting the starboard wing pushrods for the aileron control circuits until both aileron trailing edges are within 0.5°...
Page 597 A&P mechanic should verify the new pushrod distance between the two end fittings and that it is consistent with the push rod being removed. If this is not the case, contact Liberty Aerospace, Inc. Customer Service. Remove the belly panel, see chapter 53 – Fuselage.
Page 598 FLIGHT CONTROLS XL-2 AIRPLANE Place on top of the Starboard horizontal stabilizers SmartTool™ digital inclinometers as shown in Figure 27-89. Record the starboard horizontal stabilizer upper skin neutral angle. The incidence of the starboard horizontal stabilizer must be within 0.1° of the incidence of the port horizontal stabilizer.
Page 599 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-89 Location Inclinometer for horizontal stabilizer Remove tape restraining horizontal stabilizer to fuselage stub profile. Move the control column aft, fully to the stop and hold. Record the port horizontal stabilizer pitch up (trailing edge up) attitude from a SmartTool™...
Page 600 FLIGHT CONTROLS XL-2 AIRPLANE Check the clearance between the trim tab and the stabilizer. The clearance should be 0.100in minimum. See Figure 27-92. Measure the clearance between the horizontal stabilizer and the fuselage. The clearance should be more than 0.175in and less than 0.270in. See Figure 27-92.
Page 601 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-92 Tail Section Clearance Measurements Between Horizontal Stabilator and the Vertical Stabilizer 27-90 P/N 135A-970-100 REVISION ~ Page 119 of 122...
Page 602 The Bevel protractor referred to in this section is a scaled or none scaled protractor capable of measuring obtuse angles, which is available via package through Liberty Aerospace, Inc. or through the internet. For none scaled protractors set bevel protractor to rudder angle &...
Page 603 FLIGHT CONTROLS XL-2 AIRPLANE Figure 27-93 Rudder Measurements Figure 27-94 Rudder Deflection Measurements Check the clearances of the rudder to the stabilizers as shown in Figure 27-95. 27-90 P/N 135A-970-100 REVISION ~ Page 121 of 122...
Page 604 FLIGHT CONTROLS XL-2 AIRPLANE Only if disturbed verify all jam nuts on each of the rod ends within the control circuit, eight (8) places have been fully tightened. Visually check pushrods rod ends (8) for approximately equal amount of thread showing.
Page 605 FUEL SYSTEM XL-2 AIRPLANE CHAPTER 28 FUEL SYSTEM Chapter 28 P/N 135A-970-100 REVISION E Page 1 of 60...
Page 606 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 607 FUEL SYSTEM XL-2 AIRPLANE Table of Contents 28-00 ECTION ENERAL 28-10 ECTION TORAGE 10-01 ECTION ROCEDURES YSTEM NSPECTION 10-02 ECTION AMAGE LASSIFICATION 10-03 ECTION EPAIRS TO THE EPAIRING THE ANK BY ELDING EPAIRING THE ANK BY ITANIUM UTTY 10-04 ECTION...
Page 608 FUEL SYSTEM XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 28-00 P/N 135A-970-100 Page 4 of 60 REVISION B...
Page 609 FUEL SYSTEM XL-2 AIRPLANE Section 28-00 General This chapter covers the airframe fuel system from the fuel tank to the inlet of the engine fuel system and includes the following: • Fuel Tank • Fuel Boost Pump • Gascolator • Associated Tubing The location of the fuel tank is in the space frame in the area of the seat back for the pilot and passenger.
Page 610 FUEL SYSTEM XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 28-00 P/N 135A-970-100 Page 6 of 60 REVISION B...
Page 611 The fuel tank is located within the space frame and as such is not removable once the airplane has left Liberty Aerospace. If it becomes necessary to remove the fuel tank from the airplane, contact Liberty Aerospace, Inc. The only procedure presented here is for a visual inspection of the fuel tank.
Page 612 FUEL SYSTEM XL-2 AIRPLANE YSTEM NSPECTION Perform this procedure to inspect the fuel tank. EMOVE FROM THE AREA ALL SOURCES OF IGNITION VEN IF THE FUEL TANK IS DRAINED OF WELL-VENTILATED FUEL VAPORS FROM THE FUEL TANK CAN IGNITE ORK IN A...
Page 613 FUEL SYSTEM XL-2 AIRPLANE Damage Classification Section 10-02 Fuel tank failure or leakage points may be hairline cracks (L) or circles (D) as shown in the Figure 28-3. Classification is shown in Table 28-1. Figure 28-3 Damage Types Maximum Allowable...
Page 614 FUEL SYSTEM XL-2 AIRPLANE Damage Type Damage Type Minimum Maximum Repair Patch Allowable Allowable Dimensions (in) Distance Summation of Between two Damage (in) Damages (in) Circle (D) 0.25 1.5X1.5 Hairline Crack 0.50 1.5X1.5 Both 0.55 2.0X2.0 Table 28-2 Damage and Repair Classification Figure 28-5 shows the special cases of failure/leakage types.
Page 615 FUEL SYSTEM XL-2 AIRPLANE EPAIRING THE ANK BY ELDING ETAL FUEL TANKS MUST NOT BE WELDED OR SOLDERED UNLESS THEY HAVE BEEN ADEQUATELY PURGED OF FUEL FUMES EEPING A TANK FILLED WITH CARBON DIOXIDE WILL PREVENT EXPLOSION OF FUEL FUMES Fuel tanks may be repaired by welding.
Page 616 FUEL SYSTEM XL-2 AIRPLANE EPAIRING THE ANK BY ITANIUM UTTY Perform this procedure to repair the fuel tank by using Titanium putty. ® Safety instructions Devcon product found this link: http://www.devcon.com/techinfo/10760.PDF ® Thoroughly clean the surface, using Devcon Cleaner Blend 300 and a clean lint free cloth soaked with alcohol to remove all oil, grease, and dirt.
Page 617 FUEL SYSTEM XL-2 AIRPLANE Mix thoroughly using square edged mixing sticks (continuously scrape material away from sides and bottom of container) until a uniform; streak- free consistency is obtained. Spread mixed material on repair area and work firmly into substrate to ensure maximum surface contact.
Page 618 FUEL SYSTEM XL-2 AIRPLANE Fuel Tank Draining Procedure Section 10-04 This section provides the information and procedure to drain the fuel tank. Listed below is the required equipment to properly drain or defuel the fuel tank. Figure 28-7 and Figure 28-8 show the two drains for the fuel system.
Page 619 FUEL SYSTEM XL-2 AIRPLANE Perform 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. Disposal of all fuel is to be performed in accordance with local standard practices and procedures.
Page 620 FUEL SYSTEM XL-2 AIRPLANE RAINING THE Perform this procedure to drain the fuel tank. Check that all airplane electrical switches are OFF and will remain OFF for duration of procedure Check the airplane that it is in a well-ventilated location free of any ignition source.
Page 621 FUEL SYSTEM XL-2 AIRPLANE Section 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 622 FUEL SYSTEM XL-2 AIRPLANE ASCOLATOR EMOVAL Perform this procedure to remove the gascolator bowl. Defuel airplane as described in the Draining the Fuel Tank procedure on page 16 of this chapter. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 623 FUEL SYSTEM XL-2 AIRPLANE ASCOLATOR NSTALLATION Perform this procedure to install the gascolator bowl. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position. Position bowl on Gascolator body and tighten bowl-retaining ring.
Page 624 FUEL SYSTEM XL-2 AIRPLANE ASCOLATOR EMOVAL Perform this procedure to remove the gascolator. Defuel airplane as described in the Draining the Fuel Tank procedure on page 16 of this chapter. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 625 FUEL SYSTEM XL-2 AIRPLANE ASCOLATOR NSTALLATION Perform this procedure to install the gascolator. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position. Install Gascolator using the two bolts and washers removed in step 7 of the Gascolator Removal procedure.
Page 626 FUEL SYSTEM XL-2 AIRPLANE LECTRIC EMOVAL Perform this procedure to remove the electric fuel pump. Defuel airplane as described in the Draining the Fuel Tank procedure on page 16 of this chapter. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 627 FUEL SYSTEM XL-2 AIRPLANE LECTRIC NSTALLATION Perform this procedure to install the electric fuel pump. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position. Install fuel pump. Position the fuel pump such that the rubber strip is against the space frame.
Page 628 FUEL SYSTEM XL-2 AIRPLANE LECTRIC HECKOUT Perform this procedure to checkout the fuel pump system after installation. During this procedure, be watchful for any leaks. If a leak is observed, stop the procedure and investigate the source of the leak and resolve.
Page 629 FUEL SYSTEM XL-2 AIRPLANE OCKPIT ALVE EMOVAL Perform this procedure to remove the cockpit fuel valve. Defuel airplane as described in the Draining the Fuel Tank procedure on page 16 of this chapter. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 630 FUEL SYSTEM XL-2 AIRPLANE OCKPIT ALVE NSTALLATION Perform this procedure to install the cockpit fuel valve. If installed, remove the belly panel. For the procedure to remove the belly panel, see Chapter 53 – Fuselage. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 631 FUEL SYSTEM XL-2 AIRPLANE HECK ALVE EMOVAL Perform this procedure to remove the check valve. Defuel airplane as described in the Draining the Fuel Tank procedure on page 16 of this chapter. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 632 FUEL SYSTEM XL-2 AIRPLANE HECK ALVE NSTALLATION Perform this procedure to install the check valve. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position. If installed, remove the belly panel. For the procedure to remove the belly panel, see Chapter 53 –...
Page 633 FUEL SYSTEM XL-2 AIRPLANE EMOVAL Perform this procedure to remove any of the fuel lines. If any step is unique to a particular fuel line, that difference will be noted in the step. Use Figure 28-14 as a guide in locating the fuel line and mounting hardware. Figure 28-14 is not a scaled drawing of the fuel system and should be used as a reference only.
Page 634 FUEL SYSTEM XL-2 AIRPLANE NSTALLATION Perform this procedure to install any of the fuel lines in the space frame. If any step is unique to a particular fuel line, that difference will be noted in the step. Use Figure 28-14 as a guide in locating the fuel line and mounting hardware. Figure 28- 14 is not a scaled drawing of the fuel system and should be used as a reference only.
Page 635 FUEL SYSTEM XL-2 AIRPLANE Fuel System Electrical Section 20-03 This section contains information on the electrical system for the fuel system within the space frame. The electrical system consists of circuit breaker, CB029, fuel boost pump switch, SW007, fuel boost pump relay, K003, the recirculating valve, mounted on the engine, and the fuel boost pump.
Page 636 FUEL SYSTEM XL-2 AIRPLANE OOST WITCH EMOVAL Perform this procedure to remove the fuel boost pump switch. Figure 28-16 Fuel Boost Pump Switch in Center Console Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 637 FUEL SYSTEM XL-2 AIRPLANE OOST WITCH NSTALLATION Perform this procedure to install the fuel boost pump switch. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position. Attach the three wire removed in step 6 of the Fuel Boost Pump Switch Removal procedure on page 32 of this chapter.
Page 638 FUEL SYSTEM XL-2 AIRPLANE OOST ELAY EMOVAL Perform this procedure to remove the fuel boost relay. Figure 28-17 Fuel Boost Relay Removal Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position.
Page 639 FUEL SYSTEM XL-2 AIRPLANE OOST ELAY NSTALLATION Perform this procedure to install the fuel boost relay. Position the Main Battery Switch, Alternator Switch, FADEC A and B and the ignition switch in the OFF position. If the instrument console panel is place, remove the instrument console panel.
Page 640 FUEL SYSTEM XL-2 AIRPLANE Airframe Fuel System Operational Check Section 20-05 and Inspection This section contains the airframe fuel system operational check and inspection procedure. Perform this procedure anytime after performing any work of the fuel system. Refer to Figure 28-18 during this procedure.
Page 641 FUEL SYSTEM XL-2 AIRPLANE IRFRAME YSTEM PERATIONAL HECK AND NSPECTION Perform this procedure to inspect and check the fuel system in the airframe. This procedure requires a minimal amount of fuel to be in the system. Remove the belly panel from the airplane in accordance with Chapter 53 –...
Page 642 Push in circuit breaker CB003, START, to CLOSE the breaker. Move airplane to a safe designated run up area and set the parking brake. Perform a normal engine start-up in accordance with the current Liberty Aerospace Airplane Flight Manual. Run engine until the oil temperature is at or above 75°.
Page 643 FUEL SYSTEM XL-2 AIRPLANE Fuel System Troubleshooting Section 20-06 This section contains information that will aid in troubleshooting issues with the fuel system located in the fuselage. For troubleshooting information on the fuels systems associated with the engine, see Chapter 73 – Engine Fuel and Control.
Page 644 FUEL SYSTEM XL-2 AIRPLANE Complaint Possible Cause Remedy Replace (see Chapter 73 – Fuel filters clogged Engine Fuel and Control ) Adjust engine driven fuel Engine driven fuel pump pump in accordance with the Low VM1000FX displayed fuel pressure set incorrectly.
Page 645 FUEL SYSTEM XL-2 AIRPLANE Section 28-40 Fuel Indication A capacitive probe installed in the fuel tank provides a signal for the instrument panel mounted fuel contents gauge. The FADEC system senses the fuel pressure (see Chapter 72 - Engine) and displays the information on the integrated engine instrument system VM1000FX (see Chapter 77 –...
Page 646 FUEL SYSTEM XL-2 AIRPLANE ENDER EMOVAL Perform this procedure to remove the fuel sender. Comply with fire prevention precautions as described in the Draining the Fuel Tank procedure on page 16 of this chapter. Check that all airplane electrical switches are OFF and will remain OFF for the duration of procedure.
Page 647 FUEL SYSTEM XL-2 AIRPLANE ENDER NSTALLATION Perform this procedure to install the fuel sender. Comply with fire prevention precautions as described in the Draining the Fuel Tank procedure on page16 of this chapter. Check that all airplane electrical switches are OFF and will remain OFF for the duration of procedure.
Page 648 Capacitive Fuel Sender Section 40-02 The Liberty XL-2 uses a Mitchell Aircraft Product capacitive fuel sender for measuring fuel quantity when mounted inside of the fuel tank. The probe has a measurable range of 16.380¬-inches over which the entire tank contents may be read.
Page 649 FUEL SYSTEM XL-2 AIRPLANE Level Flight Attitude Section 40-03 The fuel quantity gauge system accuracy is directly affected by airplane pitch and roll attitudes. The fuel quantity gauging system is designed to be the most accurate in level flight cruise attitude (–1.7° nose up in pitch and 0° roll). The fuel indication check is conducted in this attitude in accordance with FAR 23.1337(b)(1).
Page 650 FUEL SYSTEM XL-2 AIRPLANE Aviation fuel grade 100LL has a specific expansion rate. Weight per unit of volume compensated for temperature is determined by the formula: (-0.008 x Temp °C) + 6.00 = Pounds per Gallon (Lbs) 1 Gallon (G) = 3.785 Liters (L)
Page 651 FUEL SYSTEM XL-2 AIRPLANE Fill Fuel Tank With 100LL Blue Section 40-07 Or 100 Green Aviation Fuel Only. In the calibration steps to follow, adjust the fuel level sender by means of controls located on top of the unit. See Figure 28-23 Prior to making any adjustment, verify the correct control has been identified for the calibration step being performed.
Page 652 FUEL SYSTEM XL-2 AIRPLANE Calibration Test Section 40-08 This section contains the calibration tests for the fuel system. Table 28-8 shows a list of required items to perform the calibration tests. Figure 28-24 and Figure 28-25 give an illustration of some the items need to perform the calibration tests.
Page 653 Position the airplane on a level surface. Referring to Figure 28-26, place a digital level (SmartTool 92346 or equivalent) between the two XL-2 seat backs and parallel with the centerline of airplane. Digital level should indicate a pitch of 1.7 ± 0.2° nose up.
Page 654 FUEL SYSTEM XL-2 AIRPLANE Ground the airplane in accordance with Chapter 51 – Standard Practices Structures. Drain the airplane fuel tank and Gascolator. Close Gascolator valve on completion. Remove the fuel tank drain valve and install the valve assembly shown in Figure 28-25.
Page 655 FUEL SYSTEM XL-2 AIRPLANE – G ALIBRATION ALLONS AUGE Perform the following procedure to calibrate the fuel gauge for gallons. Start with a dry tank. Turn the Master Switch – ON. On the airplane’s OAT read the current ambient temperature in degrees Celsius.
Page 656 FUEL SYSTEM XL-2 AIRPLANE Drain 7 gallons of fuel by weight. Turn the Master Switch – ON. Verify gauge reads 21 ± 1.7 Gals. See Table 28-7. Record gauge reading in Table 28-9 space provided. Turn the Master Switch – OFF.
Page 657 FUEL SYSTEM XL-2 AIRPLANE – L ALIBRATION ITERS AUGE Perform the following procedure to calibrate the fuel gauge for gallons. Start with a dry tank. Turn the Master Switch – ON. On the airplane OAT read the current ambient temperature in degrees Celsius.
Page 658 FUEL SYSTEM XL-2 AIRPLANE Record gauge reading in Table 28-10 space provided. Turn the Master Switch – OFF. Drain 20 Liters of fuel by weight. Turn the Master Switch – ON. Verify gauge reads 60 ± 4.5 Liters See Table 28-7.
Page 659 FUEL SYSTEM XL-2 AIRPLANE Fuel Indication Check – Gallons Airplane Serial Number: ______________ Airplane Registration: _______________ Fuel Indicator Serial Number: _________________ Test Date: _______________ Capacitive Fuel Sender Serial Number: ______________ Fuel Fuel Gauge Needle Fuel Quantity Gauge Pass/Fail Circle One...
Page 660 FUEL SYSTEM XL-2 AIRPLANE Fuel Indication Check – Liters Airplane Serial Number: ___________ Airplane Registration: _______________ Fuel Indicator Serial Number: __________________ Test Date: _______________ Capacitive Fuel Sender Serial Number: ______________ Fuel Fuel Gauge Needle Fuel Quantity Gauge Pass/Fail Circle One...
Page 661 FUEL SYSTEM XL-2 AIRPLANE Adjustments Section 40-09 To adjust the fuel sender, refer to Figure 28-28, turn screw as required to increase or decrease distance between 28-gallon (106-Liters) fuel gauge mark and needle location. Note that this adjustment will have an equal effect to all other indication marks.
Page 662 FUEL SYSTEM XL-2 AIRPLANE Figure 28-29 Fuel Quantity Tolerance Chart – Gallons Figure 28-30 Fuel Quantity Tolerance Chart – Liters 28-40 P/N 135A-970-100 Page 58 of 60 REVISION ~...
Page 663 FUEL SYSTEM XL-2 AIRPLANE Troubleshooting Section 40-10 This section has information to aid in troubleshooting issues with the fuel system indiicators. Complaint Possible Cause Remedy defective fuel level circuit replace breaker defective fuel level indicator replace Fuel level indicator inoperative...
Page 664 FUEL SYSTEM XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 28-40 P/N 135A-970-100 Page 60 of 60 REVISION ~...
Page 665 ICE AND RAIN PROTECTION XL-2 AIRPLANE CHAPTER 30 ICE AND RAIN PROTECTION Chapter 30 P/N 135A-970-100 REVISION C Page 1 of 22...
Page 666 XL-2 AIRPLANE Copyright © 2010 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 667 ICE AND RAIN PROTECTION XL-2 AIRPLANE Table of Contents 30-00 ECTION ENERAL 30-30 ECTION ITOT TATIC YSTEM 30-01 ECTION ITOT TATIC ROCEDURES ITOT TATIC LADE EMOVAL ITOT TATIC LADE NSTALLATION ITOT URRENT ENSOR EMOVAL ITOT URRENT ENSOR NSTALLATION ITOT ELAY...
Page 668 ICE AND RAIN PROTECTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 30 P/N 135A-970-100 Page 4 of 22 REVISION C...
Page 669: Section 30-00 General
XL-2 AIRPLANE Section 30-00 General This chapter describes systems, on the Liberty Aerospace, Inc. XL2 airplane that protects the airplane during rain and icing conditions. Although the airplane is not certified for known icing conditions, systems are provided to prevent ice formation in the wing mounted Pitot-Static Blade assembly.
Page 670 ICE AND RAIN PROTECTION XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 30-00 P/N 135A-970-100 Page 6 of 22 REVISION C...
Page 671: Section 30-30 Pitot-Static System
ICE AND RAIN PROTECTION XL-2 AIRPLANE Section 30-30 Pitot-Static System This section details the Pitot-Static system. This section contains the procedures to remove, install, and check the wing mounted pitot-static blade assembly, the heating circuit, and associated pitot-static tubing. The pitot-static system consists of the heated pitot-static blade assembly, PN...
Page 672: Pitot -Static Blade Removal
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT TATIC LADE EMOVAL Perform this procedure to remove the Pitot-Static Blade. Figure 30-3 Pull the circuit breaker for the pitot heat. Remove the three screws securing access cover closest to the pitot-static blade.
Page 673: Pitot -Static Blade Installation
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT TATIC LADE NSTALLATION Perform this procedure to install the Pitot-Static Blade. Figure 30-4 Pitot-Static Blade Installation Detail Pull the circuit breaker for the pitot heat. Remove the three screws securing access cover closest to the pitot-static blade.
Page 674 ICE AND RAIN PROTECTION XL-2 AIRPLANE Connect the purple tube to the tube coming from the forward connector marked “P”. Connect the green tube to the tube coming from the aft connector marked “S”. Connect the electrical cable to the electric cable coming from the pitot- static blade.
Page 675: Pitot Heat Current Sensor Removal
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT URRENT ENSOR EMOVAL Perform this procedure to remove the Pitot Heat Current sensor. This device contains electro-statically sensitive parts. Take ESD precautions before handling this or any other electronic device on the airplane.
Page 676 ICE AND RAIN PROTECTION XL-2 AIRPLANE Figure 30-6 Location of the Pitot Heat Current Sensor Showing Wire H03A14 Remove the two screws securing the pitot heat current sensor to the bracket. Disconnect the three-wire cable leading to the current sensor, and secure.
Page 677: Pitot Heat Current Sensor Installation
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT URRENT ENSOR NSTALLATION Perform this procedure to install the Pitot Heat Current sensor. This device contains electro-statically sensitive parts. Take ESD precautions before handling this or any other electronic device on the airplane.
Page 678 ICE AND RAIN PROTECTION XL-2 AIRPLANE Figure 30-7 Location of the Pitot Heat Current Sensor with Details of Relay K006 Secure any wiring with wire ties as needed. Install the instrument panel into the Instrument console. Secure the instrument panel with the ten screws removed earlier.
Page 679 ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT ELAY EMOVAL Perform this procedure to remove the Pitot Heat Relay. This device contains electro-statically sensitive parts. Take ESD precautions before handling this or any other electronic device on the airplane. Ensure all electrical switches are off.
Page 680 ICE AND RAIN PROTECTION XL-2 AIRPLANE Figure 30-9 Location of the Pitot Heat Relay K006 Connect an anti-static strap from you body to the metallic surface of the power distribution harness. Disconnect the wires connected to relay 006. See Figure 30-9.
Page 681: Pitot Heat Relay Installation
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT ELAY NSTALLATION Perform this procedure to install the Pitot Heat Relay. This device contains electro-statically sensitive parts. Take ESD precautions before handling this or any other electronic device on the airplane. Ensure all electrical switches are off.
Page 682 ICE AND RAIN PROTECTION XL-2 AIRPLANE Figure 30-10 Location of the Pitot Heat Relay K006 Terminals Secure any wiring with wire ties as needed. Install the instrument panel into the Instrument console. Secure the instrument panel with the ten screws removed earlier.
Page 683: Pitot -Static Pneumatic Inspection And Check Out
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT TATIC NEUMATIC NSPECTION AND HECK Perform this procedure to inspect and check the Pitot-Static Blade. Check all hardware for proper torque. For the correct torque values, see Chapter 20 – Standard Practices. Check the two inlets on the blade are clear and free of foreign material.
Page 684: Pitot -Static Electrical Inspection And Check Out
ICE AND RAIN PROTECTION XL-2 AIRPLANE ITOT TATIC LECTRICAL NSPECTION AND HECK Perform this procedure to inspect and check the pitot-static electrical system. If the pitot-static tubing has been changed or altered, perform the Pitot-Static Pneumatic Inspection and Check Out on page 19 of this chapter before performing this procedure.
Page 685: Section 30-02 Troubleshooting
ICE AND RAIN PROTECTION XL-2 AIRPLANE Section 30-02 Troubleshooting For troubleshooting information, see Chapter 34 – Navigation and Pitot-Static. 30-30 P/N 135A-970-100 REVISION C Page 21 of 22...
Page 686 ICE AND RAIN PROTECTION XL-2 AIRPLANE PAGE LEFT INTENTIONAL LEFT BLANK 30-30 P/N 135A-970-100 Page 22 of 22 REVISION C...
Page 687 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE CHAPTER 31 INDICATORS AND RECORDING SYSTEMS Chapter 31 P/N 135A-970-100 REVISION ~ Page 1 of 54...
Page 688 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 689 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Table of Contents 31-00 ECTION ENERAL 31-10 ECTION NSTRUMENT ANEL 10-01 ECTION NSTRUMENT ANEL NDICATORS 10-02 ECTION NSTRUMENT ANEL ROCEDURES NSTRUMENT ANEL EMOVAL NSTRUMENT ANEL NSTALLATION ENERAL NDICATOR EMOVAL ENERAL NDICATOR NSTALLATION 10-03 ECTION...
Page 690 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 31 P/N 135A-970-100 Page 4 of 54 REVISION ~...
Page 691 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Section 31-00 General With the exception of the trim position indicator, installed on the upper surface of the cockpit center console, all instruments and displays in the airplane are installed on the instrument console.
Page 692 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 31-00 P/N 135A-970-100 Page 6 of 54 REVISION ~...
Page 693 Aircraft electrical and subsystem switches are installed to the right of the engine instrumentation display. Instrument Panel Indicators Section 10-01 The XL-2 airplane comes equipped with the following indicators mounted to the instrument panel: • Air Speed Indicator •...
Page 694 ANEL EMOVAL Perform this procedure to remove the instrument panel from the airplane. Liberty Aerospace, Inc. recommends performing this procedure while sitting in the pilot’s seat. Have the block of soft foam cushioning in your lap that it covers the yoke assembly.
Page 695 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Figure 31-3 Rear View of the Instrument Panel Disconnect the pitot line (violet tubing) from the Airspeed indicator. Disconnect the static line (green tubing) at the altitude encoder system. Cap all lines and/or indicators. For the location of the pitot and static lines, and where to disconnect these lines, see Figure 31-3 and Figure 31-4.
Page 696 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Disconnect P03, P10, and P15 from their mating connectors on the power distribution bracket. See Figure 31-6 for location of P/J03, P/J10, and P/J15. Figure 31-6 Left Hand Side of the Power Distribution Harness Assembly Remove the instrument panel from the airplane keeping the instrument panel on its face into a block of soft foam cushioning.
Page 697 ANEL NSTALLATION Perform this procedure to install the instrument panel from the airplane. Liberty Aerospace, Inc. recommends performing this procedure while sitting in the pilot’s seat. Have the block of soft foam cushioning in your lap that it covers the yoke assembly.
Page 698 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE If the instrument panel has one or two Course Deviation Indicators (CDI), connect the electrical connectors on the back of the CDI. (P/J106-1 and/or P/J106-2) See Figure 31-9 for the location of the connectors P/J106-1 and/or P/J106-2.
Page 699 Perform this procedure to remove any of the indicators, gauges, or displays from the instrument panel. If it is necessary to remove any of the switches or controls from the instrument panel, Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane and working on it at a bench.
Page 700 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE ENERAL NDICATOR NSTALLATION Perform this procedure to install any of the indicators or gauges into the instrument panel. Ensure all electrical switches are off. If installing a replacement indicator or gauge immediately after removing an previous indicator or gauge, then proceed to step 8 below.
Page 701 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Functional Checks Section 10-03 Perform a functional check to Functional Check table. Perform a functional check on all lights and dimming features. FUNCTIONAL CHECKS Indicator Test Reference Chapter Navigation and Chapter 34 – Air speed indicator...
Page 702 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 31-10 P/N 135A-970-100 Page 16 of 54 REVISION ~...
Page 703 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Section 31-20 Independent Indicators This section describes other indicators that are independent of other systems in the airplane or are not described in other chapters in the maintenance manual. Flap Position Switch Section 20-01 The flap position switch is co-located below the flap position indicators on the avionics panel.
Page 704 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Wide Open Throttle (WOT) Indicator Section 20-05 The Wide Open Throttle, WOT, indicator is part of the flight instrument panel indicator row above and left of the airplane split master switch. When the throttle control is in the fully forward, wide-open position, an engine mounted switch closes and illuminates this green-coded LED.
Page 705 TATUS NDICATOR EMOVAL Perform this procedure to remove the health status indicator. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane and working on it at a bench. Perform the Instrument Panel Removal procedure on page 8 of this chapter.
Page 706 EALTH TATUS NDICATOR NSTALLATION Perform this procedure to install the health status indicator. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane to do this procedure. If installing a replacement indicator immediately after removing a previous indicator, then proceed to step 3 below.
Page 707 EMOVAL Perform this procedure to remove any of the LED indicators on the instrument panel. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane and working on it at a bench. Perform the Instrument Panel Removal procedure on page 8 of this chapter.
Page 708 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE LED I NSTRUMENT ANEL NDICATOR NSTALLATION Perform this procedure to install any of the LED indicators mounted to the instrument panel. If replacing the WOT LED indicator, the LED must be GREEN. If replacing the ALT FAIL, STARTER ENGAGED, or PITOT HEAT LED indicator, the LED must be YELLOW.
Page 709 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE OSITION WITCH EPLACEMENT Perform this procedure to replace a defective flap position switch. Remove the avionics radios from the avionics panel. To remove the radios, insert a hex key (“3/32” Allen wrench”) into the hole in faceplate of the radio and rotate counter-clockwise until the retaining claw is released.
Page 710 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Figure 31-12 Partial Schematic of Flap Switch Circuit Press in on the spring tabs on the top and bottom of the switch. See Figure 31-13 for details of the spring tabs. Figure 31-13 Flap Position Switch Showing the Spring Tabs While pressing in on the spring tabs, rock the switch out from the front of the avionics panel.
Page 711 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Move the flap switch to Flaps Up position. Verify the correct switch indicator illuminates, the flap actuator motor runs and the flaps are moving to the up position. As the flaps are moving from the fully down position (30°) to the fully up position (0°), verify the flap position indicators illuminate to correspond to...
Page 712 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE LED I OSITION NDICATOR EMOVAL Perform this procedure to remove the LED indicators associated with the Flap Indicator. Remove the avionics radios from the avionics panel. To remove the radios, insert a hex key (“3/32” Allen wrench”) into the hole in faceplate of the radio and rotate counter-clockwise until the retaining claw is released.
Page 713 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Mark for identification and cut the black wires ahead of splice SP019. Refer to Figure 31-15 for the schematic location of the splice. Figure 31-15 Partial Schematic of the Flap Indicator Circuit Separate P/J47.
Page 714 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE LED I OSITION NDICATOR NSTALLATION Perform this procedure to install any of the LED indicators mounted to the instrument panel. If installing a replacement indicator immediately after removing a previous indicator, then proceed to step 3 below.
Page 715 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE On the instrument console, move the Bright/Dim/Test switch to the Bright position. Verify the flaps 0 Degrees LED indicator is illuminated and bright. On the instrument console, move the Bright/Dim/Test switch to the Dim position.
Page 716 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE OSITION WITCH EPLACEMENT Perform this procedure to remove the flap position switch. This procedure is best done with two people. One person positioned under the airplane to start the switch removal and feed the wires to the switch up through the hole in the center console.
Page 717 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE As the trim tabs are moving from the neutral position to the nose down position, verify the trim tab position indicators illuminate to correspond to the trim tab position. When the trim tabs reach the nose down position, release the switch. Verify the switch moves back to the neutral position, the switch illumination is out, and the trim tab actuator motor stops running.
Page 718 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE LED I OSITION NDICATOR EMOVAL Perform this procedure to remove the LED indicators associated with the Trim Indicator. Remove the two screws holding in the center console panel assy. Refer to Figure 31-18 for the location of the two screws.
Page 719 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Use a 10mm open-end wrench to loosen and remove the nut. Slide the indicator out through the front of the center console panel. If a replacement indicator is not available, install the upper center console panel;...
Page 720 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE LED I OSITION NDICATOR NSTALLATION Perform this procedure to install any of the LED indicators mounted to the instrument panel. If installing a replacement indicator immediately after removing an previous indicator, then proceed to step 3 below.
Page 721 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Verify the trim tabs are in the Takeoff position. If the trim tabs are not in the taker-off position, use the trim switch to bring the trim tabs to the take-off position. If the trim tabs are in the Takeoff position, verify the take-off green LED indicator is illuminated.
Page 722 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE THIS PAGE LEFT INTENTIONALLY BLANK 31-20 P/N 135A-970-100 Page 36 of 54 REVISION ~...
Page 723 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Section 31-30 Recorders The XL-2 airplane has two recording systems. These are the VM-1000FX and the Engine Data Interface. This section describes both systems. VM-1000FX Engine Instrument Display Section 30-01 The VM-1000FX integrated engine instrument display system can record, and display, maximum and minimum engine operating information about each flight.
Page 724 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Engine Data Interface Section 30-02 The aircraft has an Engine Data Interface (EDI). The purpose of the system is to acquire engine data from the Serial Bus Controller (SBC-100), process data for storage, compress data, store data, and provide for ground retrieval of the stored data.
Page 725 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE NGINE NTERFACE EMOVAL Perform this procedure to remove the engine data interface annunciator. Do not attempt to remove the EDI without taking the CB panel out of the instrument console. The cabling and connectors are tie-wrapped to the EDI that must be removed before removing the EDI from the instrument console.
Page 726 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Disconnect PVM03A ribbon cable connector from the DPU PVM03 connector. See Figure 31-22 for the location of PVM03A connector. Figure 31-22 Top View of the CB Panel Showing the Connectors Disconnect Engine Data Interface,...
Page 727 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE NGINE NTERFACE NSTALLATION Perform this procedure to remove the engine data interface annunciator. Although this procedure has the ALT and BAT master switches, the FADEC PWR A & B switches, and the ignition switch in the OFF position, there is still voltage from the secondary battery on the terminal barrier strip mounted to the power distribution harness assembly behind the CB panel.
Page 728 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE NGINE NTERFACE HECKOUT Perform this procedure to checkout the Engine Data Interface unit. Position the aircraft in a safe run up area. Perform a normal start of the engine and set the throttle to idle (850 to 950 RPM).
Page 729 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE NGINE NTERFACE NITIALIZATION AND The EDI-200 begins and completes a self-test as completely as practical depending on the aircraft operational state when power is applied to the EDI. This test will power up the EDI-200 and verify a valid initialization state is achieved.
Page 730 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Receiving Data Remove power from the aircraft by deactivation of the master switch. Using inspection mirror, view the EDI LEDs and verify expected status listed below: Green LED Status Red LED Status OFF - Unit Fault Or Unit...
Page 731 XL-2 AIRPLANE Section 31-50 Stall Warning The XL-2 airplane comes with a voice alert stall warning annunciator. The annunciator connects to a lift switch mounted in the port wing. The annunciator mounts on the left side of the avionics stack, behind the avionics panel in the instrument panel console.
Page 732 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE TALL ARNING EMOVAL Perform this procedure to remove the stall warning annunciator. Position the ALT and BAT master switches, the FADEC PWR A and B switches, and the ignition switch to OFF. Pull the BAT1 (CB001) circuit breaker to OPEN.
Page 733 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Remove the connector on the side of the stall warning annunciator. Remove the three 3/16 inch nuts that secure the stall warning annunciator to the avionics panel. Remove the stall warning annunciator. If immediately installing a replace stall warning annunciator go to step of the procedure on page of this chapter.
Page 734 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE TALL ARNING NSTALLATION Perform this procedure to install the stall warning annunciator. If installing a replacement stall warning annunciator immediately after removing a previous stall warning annunciator, then proceed to step 5 below. Perform step 1 through 6 of the Stall Warning Removal procedure on page 46 of this chapter.
Page 735 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE TALL ARNING ENSOR EMOVAL Perform this procedure to remove the stall sensor. Check that all power is off on the airplane. Use a sharp permanent felt tip marker to mark the location on the plate of the switch the location of the four mounting screws.
Page 736 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE TALL ARNING ENSOR NSTALLATION Perform this procedure to install the stall sensor. If installing a replacement stall warning sensor immediately after removing a previous stall warning sensor, then proceed to step 3 below. Perform step 1 through 6 of the Stall Warning Sensor Removal procedure on page 49 of this chapter.
Page 737 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE TALL ARNING YSTEM HECK Perform this procedure to check the stall warning system. Apply power to the airplane by pressing the BAT Master switch to ON. Wait for 15 seconds to allow all system to come on line.
Page 738 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Stall Warning System Troubleshooting Section 50-02 This section provides information to trouble shoot the stall warning system. See Table 31-5 for information to troubleshoot the stall warning system. Issue Cause Repair No Power Check that power is ON.
Page 739 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE Section 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 – Engine Indicating.
Page 740 INDICATORS AND RECORDING SYSTEMS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 31-60 P/N 135A-970-100 Page 54 of 54 REVISION ~...
Page 741 LANDING GEAR XL-2 AIRPLANE CHAPTER 32 LANDING GEAR Chapter 32 P/N 135A-970-100 REVISION E Page 1 of 90...
Page 742 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 743 LANDING GEAR XL-2 AIRPLANE Table of Contents 32-00 ECTION ENERAL 32-10 ECTION ANDING 10-01 ECTION ERIODIC AINTENANCE 10-02 ECTION ANDING ROCEDURES ANDING SSEMBLY EMOVAL ANDING SSEMBLY NSTALLATION ANDING PERATIONAL HECK AND NSPECTION 10-03 ECTION ANDING EAR TROUBLESHOOTING UIDE 32-20 ECTION...
Page 744 LANDING GEAR XL-2 AIRPLANE INGER RAKE ASTER YLINDER EMOVAL INGER RAKE ASTER YLINDER NSTALLATION INGER RAKE PERATIONAL HECK AND NSPECTION 40-16 ECTION INGER RAKE ROUBLESHOOTING UIDE 40-17 ECTION HEEL RAKE ALIPER YSTEM 40-18 ECTION ERIODIC AINTENANCE 40-19 ECTION HEEL RAKE...
Page 745 XL-2 AIRPLANE Section 32-00 General The Liberty XL-2 landing gear is a fixed tricycle landing gear. All of the three landing gear wheels employ 5.00 x 5 tires (with inner tubes) inflated to a pressure of 50 +2 /-0 psi for all three tires.
Page 746 LANDING GEAR XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 32-00 P/N 135A-970-100 Page 6 of 90 REVISION ~...
Page 747 Periodic Maintenance Section 10-01 Periodic Main Landing Gear maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Main Landing Gear Procedures...
Page 748 If removing “PORT” main landing gear, disconnect electric fuel boost pump from chassis attachment. in accordance with Liberty Maintenance Manual Chapter 28 - Fuel System. Cut and remove safety wire. Remove two bolts securing brake caliper. Cut away three (3) tie-wraps around brake line and undercarriage leg.
Page 749 LANDING GEAR XL-2 AIRPLANE Figure 32-1 Exploded View of Main Landing Gear Attachment Bolt Figure 32-2 Main Landing Gear Port Attachment Bolt and undercarriage Restraint Lower (Saddle) This completes the Main Landing Gear Assembly Removal procedure. 32-10 P/N 135A-970-100 REVISION ~...
Page 750 LANDING GEAR XL-2 AIRPLANE ANDING SSEMBLY NSTALLATION Perform this procedure to install the main landing gear assembly. This procedure applies to both the port and starboard main landing gear assemblies. Any misalignment or tracking issue with the main landing gear may be an indicator of a hard landing;...
Page 751 Position the aircraft master switch OFF. Chock main wheels. Remove the belly panel in accordance with Liberty Maintenance Manual Chapter 53-Fuselage. Check Main landing gear legs for damage and deformation. Check Main landing gear port and starboard attachment bolts for condition, security and condition of bushings.
Page 752 LANDING GEAR XL-2 AIRPLANE Main Landing Gear troubleshooting Guide Section 10-03 Complaint Possible Cause Remedy Perform a hard landing inspection in accordance with Liberty Maintenance Manual Main gear leg bent Hard Landing Chapter 05 Replace main gear leg Negative camber...
Page 753 Periodic Maintenance Section 20-01 Periodic maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Nose Landing Gear Procedures Section 20-02 This section contains the procedures for the removal and installation of the nose landing gear.
Page 754 If shim is used, check the shim that it is reinstalled with leg. If shim is worn contact Liberty Customer Support. Verify no more than two washers are needed under nut during installation of tapered pin. If another washer is required, it may indicate shim (P/N 135A-04-757) not applied, Contact Liberty Customer Support.
Page 755 LANDING GEAR XL-2 AIRPLANE Figure 32-3 Nose Gear Installation This completes the nose gear assembly removal procedure. 32-20 P/N 135A-970-100 REVISION ~ Page 19 of 88...
Page 756 If shim is used, check the shim that it is reinstalled with leg. If shim is worn contact Liberty Customer Support. Verify no more than two washers are needed under nut during installation of tapered pin. If another washer is required, it may indicate shim (P/N 135A-04-757) not applied, Contact Liberty Customer Support.
Page 757 This procedure performs nose landing gear operational check and inspection. Position the aircraft master switch OFF. Chock main wheels. Remove the belly panel in accordance with Liberty Maintenance Manual Chapter 53-Fuselage. Check Nose landing gear for damage or deformation. Check Nose landing gear attachment bolts for condition and security.
Page 758 LANDING GEAR XL-2 AIRPLANE Nose Landing Gear Troubleshooting Section 20-03 Guide Complaint Possible Cause Remedy Perform a hard landing inspection in accordance with Liberty Maintenance Manual Nose gear leg bent Hard Landing Chapter 05 Replace nose gear leg Perform a hard landing...
Page 759 LANDING GEAR XL-2 AIRPLANE Section 32-40 Wheels and Brakes All three-wheel assemblies on the airplane are similar. However, only the two main wheels have disc brakes installed as shown in Figure 32-4. The main axles and nose wheel axle assemblies are different. Wheels must be disassembled for normal maintenance such as tire and tube replacement or wheel bearing service.
Page 760 LANDING GEAR XL-2 AIRPLANE • Nose Gear Fairing Forward (1) • Nose Gear Fairing Assembly Aft (2) • Main Wheel Fairing Assembly Port (3) with Port access panel (4 - not shown) • Main Wheel Fairing Assembly starboard (5) with starboard access...
Page 761 LANDING GEAR XL-2 AIRPLANE Figure 32-6 Exploded View of Main Wheel Fairing, Port Wheel Fairing Component List Item Part Number Description 135A-40-021 Main Wheel Fairing Assembly, Port 135A-40-022 Main Wheel Fairing Assembly, Starboard 135A-40-305 Spacer, Nose Wheel Fairing 135A-40-307 Spacer, Main Wheel Fairing, Inboard...
Page 762 Periodic Maintenance Section 40-02 Periodic Wheel Fairing maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Wheel Fairing Procedures...
Page 763 Check and to ensure tire pressure is 50 +2 /-0 psi. Remove hubcap (3 screws each) on both Port and starboard side; and do not reuse. Jack main landing gear in accordance with Liberty Maintenance Manual Chapter 07. Install FIRST: (Port) main brackets, spacer outboard, and supporting hardware.
Page 764 LANDING GEAR XL-2 AIRPLANE Figure 32-7 Drill Hole Location on Axle Install wheel fairing bracket using four (4) of existing eight (8) washers. Check the brake caliper that it is properly re-installed. Install spacer outboard using a socket head cap screw and apply Loctite®...
Page 765 LANDING GEAR XL-2 AIRPLANE HEEL AIRING NITIAL NSTALLATION Perform this procedure to install a nose wheel fairing on an aircraft not previously so equipped. Once initial installation of nose and main wheel fairing brackets, outboard main spacers and additional supporting hardware are installed with the aircraft wheel fairings.
Page 766 LANDING GEAR XL-2 AIRPLANE HEEL AIRING EMOVAL Perform this procedure to remove the main wheel fairings on an aircraft so equipped. Procedure is applicable to both the port and starboard main wheel fairings. Figure 32-9 Main Wheel Fairing Installation Position aircraft on a level surface and set the parking brake Remove main wheel fairing panel screws (5) and remove the wheel fairing panel as shown in Figure 32-9.
Page 767 LANDING GEAR XL-2 AIRPLANE HEEL AIRING EMOVAL Perform this procedure to remove the nose wheel fairings on an aircraft so equipped. Remove Nose Fairing Assembly Aft Nose Fairing Assembly Aft Nose Fairing Assembly Aft AN526C-1032R8 Machine Screw 10-32 AN526C-1032R8 Machine Screw 10-32...
Page 768 Figure 32-11. Small adjustments can be made prior to application of final torque. Figure 32-11 Ground Clearance Torque the fasteners in accordance with Liberty Maintenance Manual Chapter 20 – Standard Practices Airframe. Release the parking brake. Move the aircraft forward through a full tire rotation and verify the tires do not scuff against the fairing.
Page 769 Figure 32-13. Small adjustments can be made prior to application of final torque. Figure 32-13 Ground Clearance Torque the fasteners in accordance with Liberty Maintenance Manual Chapter 20 – Standard Practices Airframe. Release the parking brake. 32-40 P/N 135A-970-100...
Page 770 LANDING GEAR XL-2 AIRPLANE Rotate the nose wheel through its entire turning range of motion. Verify the nose wheel fairing and installation is free of binding, chaffing, or other interference. Roll the aircraft forward through a full tire rotation and verify the tire does not scuff on the fairing.
Page 771 LANDING GEAR XL-2 AIRPLANE HEEL AIRING PERATIONAL HECK AND NSPECTION This procedure performs wheel fairing operational checks and inspection. Inspect fairings for cracks or deformations. Inspect fairings for proper installation alignment as shown in Figure 32-14 and Figure 32-15. Figure 32-14...
Page 772 LANDING GEAR XL-2 AIRPLANE Wheel Fairing Troubleshooting Guide Section 40-04 Complaint Possible Cause Remedy Perform a hard landing inspection in accordance with Liberty Maintenance Manual Hard Landing Chapter 05 Cracked fairing Replace Ground handling Replace Align in accordance with Ground Handling Liberty Maintenance Manual Chapter 32.
Page 773 XL-2 AIRPLANE Wheels Section 40-05 Aircraft wheels fitted to the Liberty XL-2 are designed and qualification tested in accordance with TSO C26 for the tire type and size matching the aircraft requirements. Operating the wheel assembly with unapproved tires, improper inflation pressures or subjected to loads in excess of design is a violation of the wheel certification basis and is prohibited.
Page 774 LANDING GEAR XL-2 AIRPLANE HEEL EMOVAL Perform this procedure to remove the nose wheel. Chock two wheels that will not be removed. Do not apply parking brake if removing/replacing a main wheel. Jack airplane to lift wheel to be removed just clear of floor, see Chapter 07 –...
Page 775 LANDING GEAR XL-2 AIRPLANE HEEL NSTALLATION Perform this procedure to install the nose wheel. Check that wheel bearings are greased and installed. Install nose wheel axle and spacer; torque jam nut (NAS509-17) to 25 in-lbs to seat bearing. Back jam nut off to 0 in-lbs; re-torque to 15-25 in-lbs.
Page 776 LANDING GEAR XL-2 AIRPLANE HEEL EMOVAL Perform this procedure to remove the main wheel It is unnecessary to disconnect medium pressure hose to caliper. Do not apply parking brake or operate any brake system when removing or installing a main wheel.
Page 777 LANDING GEAR XL-2 AIRPLANE HEEL NSTALLATION Perform this procedure to install the main wheel. Check the wheel that it has been properly reassembled after service. Inflate tire to 50 +2 / -0 psi (all wheels). Figure 32-19 Main Landing Gear Wheel Spray dry film lubricant on main gear axle and axle spacers.
Page 778 LANDING GEAR XL-2 AIRPLANE Rotate wheel/tire while tightening axle nut to 150 – 200 in-lb to seat bearing. Back off axle nut to zero torque. Tighten axle nut to 30 – 40 in-lb while rotating wheel/tire. Rotate axle nut (clockwise or counterclockwise) to nearest slot and split pin hole.
Page 779 LANDING GEAR XL-2 AIRPLANE HEEL PERATIONAL HECK AND NSPECTION This procedure performs main and nose wheel operational and checks and inspections. Position aircraft in a level location and chock wheels not undergoing operation check or inspection. Check tires for condition, wear, proper inflation (50 psi -0/+2 psi).
Page 780 Main landing gear alignment Replace tire if worn to tire manufacturers tread limit. Tire wear Inspect nose wheel assembly in accordance with Liberty Maintenance manual Chapter Nose wheel shimmy Replace tire if worn below tire manufacturers tread limit Landing in crabbing position in...
Page 781 LANDING GEAR XL-2 AIRPLANE Complaint Possible Cause Remedy Replace bearing and repack Lack of bearing grease with grease. Replace bearing cone being Misalignment of bearings sure it is properly seated in bearing bore Replace bearing cone being sure it is properly seated in...
Page 782 LANDING GEAR XL-2 AIRPLANE Toe Brake System Section 40-09 The airplane uses independent disc brakes on the port and starboard main landing gear for both deceleration and low-speed (taxi) steering. In a toe brake installation, a master cylinder is mounted on each of the four rudder legs and actuated by a toe pad at the bottom of each leg.
Page 783 LANDING GEAR XL-2 AIRPLANE The Parking Brake Lever shown Figure 32-21 is located to the right of the throttle lever and operates a simple hydraulic valve. When open, hydraulic fluid is free to flow in both directions. When closed hydraulic fluid can only flow to the caliper under pressure produced by actuating the brake toe pad.
Page 784 Periodic Maintenance Section 40-11 Periodic Toe Brake System maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Toe Brake Procedures...
Page 785 LANDING GEAR XL-2 AIRPLANE RAKE ASTER YLINDER EMOVAL Perform this procedure to remove the master cylinder mounted to the rudder pedals. The reservoir is located engine bay, starboard under upper engine cowl aft of firewall. Access to four master cylinders located on each of four rudder pedal weldments is via cockpit: Minor spillage of brake fluid is unavoidable when master cylinders are removed.
Page 786 LANDING GEAR XL-2 AIRPLANE Note the clocking angle of the elbow fittings from the master cylinder removed. See Figure 32-25 for the correct clocking angles for the brake line fittings. Figure 32-25 Clocking of the Brake Line Fittings Remove and discard master cylinder and associated elbow fittings.
Page 787 LANDING GEAR XL-2 AIRPLANE RAKE ASTER YLINDER NSTALLATION Perform this procedure to install the master cylinder for the toe brakes. Vendor for brake master cylinder P/N 10-55A is Parker Hannifin Corp., Ravenna, OH. During assembly, check that mounting bolts are normal to longitudinal centerline of brake master cylinder;...
Page 788 LANDING GEAR XL-2 AIRPLANE Fully engage self-locking castellated nut 10-32, then back off half turn to nearest castellated slot. Check the bolt (AN3-11, 10-32) that it freely spins by hand so as not to hinder movement of bell crank. Install adjusted master cylinder with original bolts (AN3-11, 10-32), washers, new self-locking castellated nuts and fit new split pins, 2 places.
Page 789 LANDING GEAR XL-2 AIRPLANE RAKE ENTER EMOVAL AND NSTALLATION Perform this procedure to remove and then install the toe brake Over-Center stop. The item numbers called out are shown in Figure 32-28. Remove (item #1) P/N: MS24694S59 screw 10-32 from bellcrank, remove...
Page 790 LANDING GEAR XL-2 AIRPLANE ARKING RAKE ALVE EMOVAL Perform this procedure to remove the parking brake valve used with the toe brake system. There are two different valves used for the parking brake. The valves are functionally interchangeable; however, do not replace a later valve with the earlier valve.
Page 791 LANDING GEAR XL-2 AIRPLANE ARKING RAKE ALVE NSTALLATION Perform this procedure to install the parking brake valve used with the toe brake system. Vender Matco. Device is not a serviceable item. Check disturbed brake lines to make sure they are recovered back to original alignment.
Page 792 PERATIONAL HECK AND NSPECTION This procedure performs toe brake operational check and inspection. Remove the upper cowl in accordance with Liberty Maintenance Manual Chapter 71-Powerplant. Remove the belly panel in accordance with Liberty Maintenance Manual Chapter 53-Fuselage. Fill the brake reservoir with MIL-H-5606 hydraulic fluid to the indicated full line.
Page 793 LANDING GEAR XL-2 AIRPLANE Toe Brake Troubleshooting Guide Section 40-13 Complaint Possible Cause Remedy Inspect system for leaking fitting and repair. Bleed brake system in Air in the brake system accordance Brake Bleeding Procedure on page 74 of this chapter.
Page 794 LANDING GEAR XL-2 AIRPLANE Complaint Possible Cause Remedy Brake reservoir air bubbles Bleed brake system in after system test accordance Brake Bleeding Air in the brake system Procedure on page 74 of this chapter. Piston cocked in cylinder, Remove and repair cylinder or resulting in overheating brake piston, or replace brake.
Page 795 LANDING GEAR XL-2 AIRPLANE Complaint Possible Cause Remedy Bent/cracked torque plate Replace Restriction in hydraulic line Isolate and remove restriction Lining not firmly seated flush Debur rivet hole on surface adjacent to lining against pressure/back plate Finger Brake System Section 40-14...
Page 796 Periodic Maintenance Section 40-15 Periodic Finger Brake System maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Finger Brake System Procedures...
Page 797 LANDING GEAR XL-2 AIRPLANE INGER RAKE ASTER YLINDER EMOVAL Perform this procedure to remove the master cylinder for the finger brakes. For the low-pressure brake line (translucent), it is permissible to disconnect and re- assemble compression nuts at the “TEE Fitting” and the three “Elbow Fittings”.
Page 798 LANDING GEAR XL-2 AIRPLANE Disconnect line from reservoir to master cylinder and cap or plug. Remove and discard split pin from castellated nuts securing front and rear bolts of master cylinder to cockpit operating lever and to fuselage center section space frame.
Page 799 LANDING GEAR XL-2 AIRPLANE INGER RAKE ASTER YLINDER NSTALLATION Perform this procedure to install the master cylinder fro the finger brakes. Parker Hannifin Corporation, Ravenna, OH, master cylinder P/N 10-55A must be in fully extended position to ensure correct operation. And all mounting bolts centers normal to longitudinal centerline of master cylinder.
Page 800 PERATIONAL HECK AND NSPECTION This procedure performs toe brake operational check and inspection. Remove the upper cowl in accordance with Liberty Maintenance Manual Chapter 71-Powerplant. Remove the belly panel in accordance with Liberty Maintenance Manual Chapter 53-Fuselage. Fill the brake reservoir with MIL-H-5606 hydraulic fluid to the indicated full line.
Page 801 LANDING GEAR XL-2 AIRPLANE Finger Brake Troubleshooting Guide Section 40-17 Complaint Possible Cause Remedy Inspect system for leaking fitting and repair. Bleed brake system in Air in the brake system accordance Brake Bleeding Procedure on page 74 of this chapter.
Page 802 LANDING GEAR XL-2 AIRPLANE Complaint Possible Cause Remedy Brake pads worn to limits Replace brake pads Bleed brake system in accordance Brake Bleeding Procedure on page 74 of this chapter. Bleed brake system in Brake reservoir air bubbles accordance Brake Bleeding...
Page 803 Periodic Maintenance Section 40-19 Periodic Main Wheel Brake Caliper System maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section.
Page 804 LANDING GEAR XL-2 AIRPLANE For Toe Brake System: move parking brake lever to “ON.” Do not operate toe brakes, there is no requirement to drain reservoir. For Finger Brake System, do not apply parking brake or operate finger brakes. It is recommended to siphon or drain reservoir.
Page 805 Perform this procedure to remove the main wheel caliper. Removal of the entire caliper assembly is performed on condition mandating replacement of the caliper assembly. For caliper pad replacement is done in accordance with Liberty Maintenance Manual Chapter 32-Landing Gear section titled Brake Caliper Pad/Liner Replacement.
Page 806 LANDING GEAR XL-2 AIRPLANE The following step is not required if the torque plate is serviceable. Perform this step if a condition requiring replacement of the caliper torque plate exists. Remove four (4) NAS6204-30 internally wrenching bolts, nuts and washers securing the axle and caliper torque plate to the main landing gear leg.
Page 807 Caliper Torque Plate Installation Install main wheel in conjunction with new caliper torque plate in accordance with Liberty Maintenance Manual Chapter 32-Landing Gear Set tire inflation to 50 + 2 / -0 psi all wheels. Reconnect medium pressure brake hose line.
Page 808 Torque tie bolts to 75-80 in-lb. Safety wire bolt heads using 0.032 safety wire MS20995 Type 203/204. Bleed and perform operational check per Liberty Maintenance Manual Chapter 32-Landing Gear. If so equipped, install the affected main wheel fairing in accordance with Liberty Maintenance Manual Chapter 32-Landing Gear.
Page 809 Do not operate any toe brake pedal, finger brake lever or parking brake lever while brake calipers are dismantled. Chock all wheels Remove main landing gear wheel fairing in accordance with Liberty Maintenance Manual Chapter 32-Landing Gear. Cut and remove safety wire and remove tie bolts, securing back plate to main caliper body.
Page 810 LANDING GEAR XL-2 AIRPLANE Caliper Assembly 30-9C Caliper Assembly 30-9C Caliper Assembly 30-9C Caliper Assembly 30-9C FIG. PART NUMBER FIG. PART NUMBER DESCRIPTION DESCRIPTION 091-04800 091-04800 Cylinder Assy. Cylinder Assy. 061-03901 061-03901 Cylinder Cylinder 092-00200 092-00200 Piston Assy. Piston Assy.
Page 811 LANDING GEAR XL-2 AIRPLANE Inspect pressure plate and back plate for excessive corrosion, visible damage, or excessive warping. The pressure plate should not be used if warped in excess of 0.010 inch (0.254 mm) flatness. Correct by using draw flattening or straightening technique shown in Figure 32-38.
Page 812 Locate brake pad back plate on backside of disc and secure with 2 caliper bolts. Torque caliper bolts 75-80 in-lbs. and install safety wire. Bleed brake system in accordance with Liberty Maintenance Manual Chapter 32-Landing Gear The following steps perform brake lining conditioning. All new brake lining installations require this conditioning procedure in order to assure maximum braking performance.
Page 813 LANDING GEAR XL-2 AIRPLANE This conditioning procedure will wear off high spots and generate sufficient heat to create a thin layer of glazed material at the lining friction surface. Normal brake usage should generate enough heat to maintain the glaze throughout the life of the lining.
Page 814 LANDING GEAR XL-2 AIRPLANE RAKE LEEDING ROCEDURE Perform this procedure to bleed the brake system. This procedure requires the use of a pressure bleeder: either a hand-pump pressure accumulator or a 12 volt pump, both compatible with MIL-H-5606 hydraulic fluid. It is necessary to pump hydraulic fluid through the Port and starboard brake bleeder simultaneously.
Page 815 LANDING GEAR XL-2 AIRPLANE Open “ON/OFF” valve and check the hydraulic fluid in feed line from pressure bleeder that it is flowing freely with no air bubbles and no bubbles in line. Fit over Port and starboard bleed nipple with minimum fluid loss.
Page 816 HECK AND NSPECTION This procedure performs toe brake operational check and inspection. Remove the upper cowl in accordance with Liberty Maintenance Manual Chapter 71-Powerplant. The following procedure applies to either a toe brake fitted aircraft or a finger brake fitted aircraft.
Page 817 Verify hydraulic fluid in the brake reservoir is still full and free of air bubbles. Install the belly panel in accordance with Liberty Maintenance Manual Chapter 53-Fuselage. Install the upper cowl in accordance with Liberty Maintenance Manual Chapter 71-Powerplant.
Page 818 LANDING GEAR XL-2 AIRPLANE This completes the brake caliper operation check and inspection procedure. Main Wheel Caliper System Section 40-21 Troubleshooting Guide Complaint Possible Cause Remedy Liner worn below limits Replace liners Liner damaged Perform liner conditioning procedure in accordance with...
Page 819 Figure 32-29. Periodic Maintenance Section 50-01 Periodic Steering maintenance entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Steering Procedures...
Page 820 Remove the belly panel in accordance with Chapter 53-Fuselage. Record the nose gear has the serial number etched on the flat aft face of the leg (see Figure 32-28). Contact Liberty Aerospace Customer Support for a the correct nose under carriage friction base as follows: •...
Page 821 LANDING GEAR XL-2 AIRPLANE Figure 32-42 Nose Wheel Steering Assembly Install the belly panel in accordance with Chapter 53-Fuselage - Fuselage. This completes the nose gear leg serial number verification procedure. 32-50 P/N 135A-970-100 REVISION ~ Page 81 of 90...
Page 822 LANDING GEAR XL-2 AIRPLANE ASTOR RICTION EMOVAL Perform this procedure to remove the castor stop/friction base. Chock both main landing gear wheels. Fasten tail tie-down to tail stand weighing at least 300 lbs. If a tail stand is not available, place a pad under tail ensuring rudder is free to move. Place 50 –...
Page 823 LANDING GEAR XL-2 AIRPLANE ASTOR RICTION NSTALLATION Perform this procedure to install the castor stop/friction base. 1. Orientation of washers: lower three with cone shape pointing down, upper three with cone shape pointing up. 2. Nose gear legs with a serial number 8940-6750 through 8940-6769 indicated on aft end of gear leg requires a matching castor stop (steel friction base P/N 135A-04-727).
Page 824 LANDING GEAR XL-2 AIRPLANE Figure 32-43 Exploded View of Nose Wheel Steering Assembly This completes the castor stop/friction base installation procedure. 32-50 P/N 135A-970-100 Page 84 of 90 REVISION ~...
Page 825 LANDING GEAR XL-2 AIRPLANE HIMMY AMPER ORQUE Perform this procedure to test the torque damper for nose gear shimmy. Temporarily install split pin (P/N MS24665-428) to prevent castle nut (MS17825-10) from backing off during nose wheel axle pull testing. Place a small strip of masking tape on nose wheel castor upper thrust washer and another one on top of nose wheel castor assembly.
Page 826 LANDING GEAR XL-2 AIRPLANE Using a calibrated force gauge, perform Nose Gear Shimmy Damper Torque Test. Nose wheel tire must be off ground. For reference, Liberty’s Quality Assurance personnel use a calibrated Mark-10 model MG100 load cell for this inspection.
Page 827 LANDING GEAR XL-2 AIRPLANE TEERING PERATIONAL HECK AND NSPECTION Perform this procedure to inspect and maintain the nose gear steering. Remove castor stop/friction base in accordance with procedure on page 82 of this chapter. There are six Belleville spring washers; a friction base and a friction pad constitute key elements of mechanical shimmy damper mechanism.
Page 828 Friction pad nominal thickness should be 0.125-inch. Liberty recommends replacement at next maintenance event, not exceeding 25 flight hours, if part has deep grooves or more than a 10% loss of thickness (minimum thickness of 0.112 in).
Page 829 LANDING GEAR XL-2 AIRPLANE Steering Troubleshooting Guide Section 50-03 Complaint Possible Cause Remedy Perform nose shimmy dampener test in accordance Shimmy dampener fault with Liberty Maintenance Manual Chapter 32-Landing Nose tire irregular wear Gear Inflate tires to standard 50 +2/-...
Page 830 LANDING GEAR XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 32-50 P/N 135A-970-100 Page 90 of 90 REVISION ~...
Page 831 LIGHTS XL-2 AIRPLANE CHAPTER 33 LIGHTS Chapter 33 P/N 135A-970-100 REVISION C Page 1 of 38...
Page 832 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 833 LIGHTS XL-2 AIRPLANE Table of Contents 33-00 ECTION ENERAL 33-10 ECTION LIGHT OMPARTMENT 10-01 ECTION NTERNAL NSTRUMENT IGHTING 10-02 ECTION IGHTING 10-03 ECTION VERHEAD IGHTING 10-04 ECTION IGHTING ROCEDURES AC I NVERTER EMOVAL AC I NVERTERS NSTALLATION ANEL IGHT IMMER...
Page 834 LIGHTS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 33 P/N 135A-970-100 Page 4 of 38 REVISION C...
Page 835 LIGHTS XL-2 AIRPLANE Section 33-00 General The airplane lighting system includes interior (flight compartment) and exterior (position, anti-collision, and landing) lights. The interior lighting consists of energy efficient super bright Light Emitting Diodes (LEDs) or LED panels and electro-luminescent panels. These devices provide sufficient light to allow the pilot to see instruments and to read charts without being too bright as to blind the pilot at night.
Page 836 LIGHTS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 33-00 P/N 135A-970-100 Page 6 of 38 REVISION ~...
Page 837 LIGHTS XL-2 AIRPLANE Section 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 838 LIGHTS XL-2 AIRPLANE Overhead Lighting Section 10-03 Maintenance for the overhead light is limited to identification and repair of defective wiring or replacement of the overhead LED light unit. Lighting Procedures Section 10-04 This section has the removal and installation procedures for the following assemblies: •...
Page 839 AC I NVERTER EMOVAL Perform this procedure to remove the DC to AC inverter. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane to do this procedure. Remove the instrument panel from the airplane. See Chapter 31- Indicators and Recording Systems (Revision D), Section 31-10-02, for the procedure to remove the instrument panel.
Page 840 AC I NVERTERS NSTALLATION Perform this procedure to install the DC to AC inverter. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane to do this procedure. For a schematic of this circuit, see Chapter 91 – Wiring Diagrams.
Page 841 LIGHTS XL-2 AIRPLANE Install the instrument panel in to the instrument console. See Chapter 31- Indicators and Recording Systems for the procedure to install the instrument panel. Perform the Flight Compartment Lighting Functional Check on page 18 of this chapter.
Page 842 Perform this procedure to remove the panel light dimmer controls. Both dimmer controls are located in the same area of the instrument panel and are removable using this procedure. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane to do this procedure.
Page 843 LIGHTS XL-2 AIRPLANE ANEL IGHT IMMER ONTROLS NSTALLATION Perform this procedure to install the panel light dimmer control. Both dimmer controls are located in the same area of the instrument panel and maybe installed using this procedure. For a schematic of this circuit, see Chapter 91 – Wiring Diagrams.
Page 844 LIGHTS XL-2 AIRPLANE Figure 33-2 Light Dimmer Wiring Secure the loose wires with cable ties. Secure the Health Status Annunciator using the hardware removed in step 3 of the DC to AC Inverter Removal procedure. Connect the three connectors that go to the Health Status Annunciator.
Page 845 The removal of the luminaries is the same for all of the instruments. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane to do this procedure.
Page 846 NSTRUMENT EZEL UMINARIES NSTALLATION Perform this procedure to install the flight instrument bezel luminaries. Liberty Aerospace, Inc. recommends removing the instrument panel from the airplane to do this procedure. If installing a replacement instrument bezel luminary immediately after removing a previous instrument bezel luminary, then proceed to step 5 below.
Page 847 LIGHTS XL-2 AIRPLANE Secure the Health Status Annunciator using the hardware removed in step 3 of the DC to AC Inverter Removal procedure. Connect the three connectors that go to the Health Status Annunciator. Secure the loose wires with cable ties.
Page 848 LIGHTS XL-2 AIRPLANE LIGHT OMPARTMENT IGHTING UNCTIONAL HECK Perform the following procedure any time interior lighting systems have been serviced. Refer to the troubleshooting guide to follow for corrective actions as required. Position BAT1 circuit breaker – CLOSED Position LIGHTS, CABIN circuit breaker – CLOSED Position LIGHTS, INST circuit breaker –...
Page 849 LIGHTS XL-2 AIRPLANE Rotate lower DIMMER control fully counter clockwise Position Avionics Master Switch - OFF Position cabin light switch – ON Verify cabin light is on. Verify LIGHT, CABIN circuit breaker remains – CLOSED Position cabin light switch - OFF Position aircraft split master switch –...
Page 850 LIGHTS XL-2 AIRPLANE Troubleshooting Guide Section 10-05 The following table has a guide to troubleshooting the flight compartment lighting. Complaint Possible Cause Remedy defective LIGHTING circuit replace circuit breaker All interior lights except breaker overhead light inoperative defective wiring repair...
Page 851 LIGHTS XL-2 AIRPLANE Section 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 852 LIGHTS XL-2 AIRPLANE Power for all four of incandescent fixture bulbs is through the 10-amp LIGHTS, NAV circuit breaker. Power for all four of the super-bright LED bulbs is through the 2-amp LIGHTS, NAV circuit breaker. The LIGHTS, POSITION switch located on the flight instrument panel controls the power going to all of the NAV and POSITION lights.
Page 853 LIGHTS XL-2 AIRPLANE OSITION IGHT EMOVAL NCANDESCENT Perform this procedure to remove the position light bulbs. Procedure applies to port or starboard light installations as required. This procedure is for wingtip light assemblies that have a standard incandescent bulb. Skin oils on the surface of position light bulbs or anti-collision light flash tubes will significantly shorten bulb/flash tube life.
Page 854 LIGHTS XL-2 AIRPLANE OSITION IGHT NSTALLATION NCANDESCENT Perform this procedure to install the position light. Procedure applies to port or starboard installations as required. This procedure is for wingtip light assemblies that have a standard incandescent bulb. Skin oils on the surface of position light bulbs or anti-collision light flash tubes will significantly shorten bulb/flash tube life.
Page 855 LIGHTS XL-2 AIRPLANE (LED O IGHT IXTURE EMOVAL Perform this procedure to remove the LED wing tip light fixture. Procedure applies to port or starboard light installations as required. LED elements are integrated in the fixture base. Navigation and position LED lights are replaced by replacement of the fixture base or the entire fixture assembly.
Page 856 LIGHTS XL-2 AIRPLANE Figure 33-6 For the starboard light fixture, disconnect the connectors P/J 50 and P/J 64. For the portside light fixture, disconnect connector P/J-49, and P/J-59. Remove screws securing lens retainer (cover). Remove the three screws securing the light fixture Feed the cable assembly out of the wing tip.
Page 857 LIGHTS XL-2 AIRPLANE (LED O IGHT IXTURE NSTALLATION Perform this procedure to install the wing tip light fixture. Procedure applies to port or starboard light installations as required. LED elements are integrated in the fixture base. Navigation and position LED lights are replaced by replacement of the fixture base or the entire fixture assembly.
Page 858 LIGHTS XL-2 AIRPLANE OLLISION LASH EMOVAL NCANDESCENT Perform this procedure to remove anti-collision flash tubes. This procedure is for wingtip light assemblies that have a standard incandescent bulb. Procedure applies to port or starboard installations as required. COLLISION STROBE LIGHT SYSTEMS CAN GENERATE DANGEROUS OR LETHAL...
Page 859 LIGHTS XL-2 AIRPLANE Locate and disconnect P49 (Port) or P50 (Starboard) Remove pins from P49 (Port) or P50 (Starboard) Remove braided sleeve and retain for later use. Slide flash tube wires out of the light assembly through a rubber grommet located at the center of the assembly.
Page 860 LIGHTS XL-2 AIRPLANE OLLISION LASH NSTALLATION NCANDESCENT Perform this procedure to install anti-collision flash tubes. This procedure is for wingtip light assemblies that have a standard incandescent bulb. Procedure applies to port or starboard installations as required. COLLISION STROBE LIGHT SYSTEMS CAN GENERATE DANGEROUS OR LETHAL...
Page 861 LIGHTS XL-2 AIRPLANE (LED O OLLISION LASH EMOVAL Perform this procedure to remove anti-collision flash tubes. This procedure is for wingtip light assemblies that have a super-bright LED bulb. Procedure applies to port or starboard installations as required. COLLISION STROBE...
Page 862 LIGHTS XL-2 AIRPLANE Locate and disconnect P49 (Port) or P50 (Starboard) Remove pins from P49 (Port) or P50 (Starboard) Remove braided sleeve and retain for later use. Slide flash tube wires out of the light assembly through a rubber grommet located at the center of the assembly.
Page 863 LIGHTS XL-2 AIRPLANE (LED O OLLISION LASH NSTALLATION Perform this procedure to install anti-collision flash tubes. This procedure is for wingtip light assemblies that have a super-bright LED bulb. Procedure applies to port or starboard installations as required. COLLISION STROBE...
Page 864 LIGHTS XL-2 AIRPLANE ANDING IGHT EMOVAL Perform this procedure to remove the landing light. Position aircraft split master switch - OFF Position circuit breaker BAT1 - OPEN Ensure all electrical switches are OFF. Remove the upper and lower engine cowling in accordance with applicable sections of the AMM Chapter 71, Powerplant.
Page 865 LIGHTS XL-2 AIRPLANE ANDING IGHT NSTALLATION Perform this procedure to install the landing light. Position aircraft split master switch - OFF Position circuit breaker BAT1 - OPEN Install landing light assembly into the lower cowling. Secure with screws and nuts removed previously.
Page 866 LIGHTS XL-2 AIRPLANE XTERIOR IGHTING UNCTIONAL HECK Perform the following procedure any time exterior lighting systems have been serviced. Refer to the troubleshooting guide to follow for corrective actions as required. Position BAT1 circuit breaker – ON Position LIGHTS, NAV circuit breaker – CLOSED Position LIGHTS, LAND circuit breaker –...
Page 867 LIGHTS XL-2 AIRPLANE Troubleshooting Guide Section 40-05 Table 33-3 is a troubleshooting guide to resolve issues with the position/anti- collision/landing light systems. Complaint Possible Cause Remedy replace bulb (incandescent) defective bulb replace the wingtip light Any single position light assembly (LED)
Page 868 LIGHTS XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 33-40 P/N 135A-970-100 Page 38 of 38 REVISION C...
Page 869 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE CHAPTER 34 NAVIGATION AND PITOT/STATIC Chapter 34 P/N 135A-970-100 REVISION B Page 1 of 116...
Page 870 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 871 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Table of Contents 34-00 ECTION ENERAL 34-10 ECTION LIGHT NVIRONMENT 10-01 ECTION ITOT TATIC YSTEM 10-02 ECTION ERIODIC AINTENANCE 10-03 ECTION ITOT TATIC YSTEM ROCEDURES ITOT TATIC YSTEM URGE TATIC YSTEM PERATIONAL HECK ITOT YSTEM...
Page 872 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE 34-20 ECTION TTITUDE AND IRECTION 20-01 ECTION AGNETIC OMPASS 20-02 ECTION ERIODIC AINTENANCE 20-03 ECTION AGNETIC OMPASS ROCEDURES AGNETIC OMPASS EMOVAL AGNETIC OMPASS NSTALLATION AGNETIC OMPASS AND RACKET NSTALLATION (“S ”) P AGNETIC OMPASS OMPENSATION...
Page 873 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE 34-50 ECTION EPENDENT OSITION ETERMINING 50-01 GPS R ECTION ECEIVER 50-02 ECTION ERIODIC AINTENANCE 50-03 GPS R ECTION ECEIVER ROCEDURES GPS S YSTEM PERATIONAL HECKOUT 50-04 ECTION ROUBLESHOOTING UIDE 50-05 ECTION RANSPONDER 50-06 ECTION ERIODIC...
Page 874 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK Chapter 34 P/N 135A-970-100 Page 6 of 116 REVISION ~...
Page 875 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Section 34-00 General Navigation instruments 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 876 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 34-00 P/N 135A-970-100 Page 8 of 116 REVISION ~...
Page 877 XL-2 AIRPLANE Section 34-10 Flight Environment Data The Liberty Xl-2 is equipped with a pitot static system providing air data to an airspeed indicator, altimeter, and vertical speed indicator. Additional air data temperature data is provided by means of a solid-state OAT probe and display that provides clock functions.
Page 878 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ITOT TATIC YSTEM URGE Perform this procedure to purge the Pitot/Static system. Use only dry nitrogen (not “shop” compressed air) to purge pitot and/or static lines. To avoid damage to instruments, check the pitot line that it 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 instruments).
Page 879 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Airspeed Static and Pitot Connection Airspeed Static and Pitot Connection Airspeed Static and Pitot Connection Airspeed Static and Pitot Connection Altim eter to Airspeed Static Line Altim eter to Airspeed Static Line Altim eter to Airspeed Static Line...
Page 880 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Reconnect static line to “T” or “L” junction. Reinstall instrument panel. Perform the static and pitot leak checks as described in Static System Operational Check on page 13 and This completes the static system operational check procedure.
Page 881 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE TATIC YSTEM PERATIONAL HECK This procedure performs an operational check of the static system by testing for system leaks. The following are precautions that should be taken when performing the static system operational checks: • Verification that the pressure inside the pitot system is equal to or greater than the static system •...
Page 882 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Check for any alterations or deformations of the airframe surface that have been made that would affect the relationship between air pressure in the static pressure system and true ambient static air pressure for any flight condition.
Page 883 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ITOT YSTEM PERATIONAL HECK This procedure performs an operational check of the pitot system by testing for system leaks. The following are precautions that should be taken when performing the pitot system operational check: • Verification that the pressure inside the pitot system is equal to or greater than the static system •...
Page 884 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 10-04 This section has the troubleshooting guide. Refer to Table 34-1 for the troubleshooting guide. Complaint Possible Cause Remedy • Drain / purge Blocked or contaminated pitot Airspeed indicator inaccurate connection or erratic (other static •...
Page 885 Periodic Maintenance Section 10-06 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Altimeter Procedures Section 10-07 This section contains the altimeter removal and installation procedures.
Page 886 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE LTIMETER EMOVAL Perform this procedure to remove the altimeter. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 887 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Install caps on to the end of the static line and on to the static port on the altimeter to prevent moisture from entering into the static line or altimeter. Remove (4) panel screws and remove instrument.
Page 888 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE LTIMETER NSTALLATION Perform this procedure to install the altimeter into the instrument panel. Check that all electrical switches are OFF. If installing a new altimeter immediately after removing an old altimeter, then proceed to step 8 below.
Page 889 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PERATION HECK Perform the following procedure to check the operation of the altimeter. Check the Static lines are free entrapped moisture and restrictions. Evacuate the static pressure system to a pressure differential of approximately 1.0 inch of mercury or to a reading on the altimeter of 1,000 feet above the aircraft elevation at the time of the test.
Page 890 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 10-08 Table 34-2 is a troubleshooting guide to resolve issues the altimeter. Complaint Possible Cause Remedy • Drain / purge Blocked or contaminated static Altimeter indicator inaccurate connection or erratic (other static •...
Page 891 Periodic Maintenance Section 10-10 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Transponder Altitude Encoder Procedures...
Page 892 EMOVAL Perform the following procedure to remove the transponder altitude encoder from the airplane. Liberty Aerospace, Inc. recommends to remove the instrument panel from the airplane while working on the transponder altitude encoder. Have the block of soft foam cushioning in your lap that it covers the yoke assembly.
Page 893 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Disconnect the pitot line (violet tubing) from the Airspeed indicator. Disconnect the static line (green tubing) at the altitude encoder system. Cap all lines and/or indicators. For the location of the pitot and static lines, and where to disconnect these lines, see Figure 34-10 and Figure 34-11.
Page 894 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Figure 34-13 Left Hand Side of the Power Distribution Harness Assembly Remove the instrument panel from the airplane keeping the instrument panel on its face into a block of soft foam cushioning. Thumb Screw Static Line...
Page 895 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE RANSPONDER LTITUDE NCODER NSTALLATION Perform this procedure to install the transponder altitude encoder. If the instrument panel is in the instrument console, then do step 1 through step 7 of the Transponder Altitude Encoder Removal procedure on page 24 of this chapter.
Page 896 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Figure 34-16 Location of the Connector on the VM1000FX If the instrument panel has one or two Course Deviation Indicators (CDI), connect the electrical connectors on the back of the CDI. (P/J106-1 and/or P/J106-2) See Figure 34-17 for the location of the connectors P/J106-1 and/or P/J106-2.
Page 897 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Figure 34-18 Location of the Ten Screws Securing The Instrument Panel Perform Transponder Altitude Encoder Operational Check on page 30 of this chapter. The factory calibrates the SAE5-35 to a pressure datum traceable to the National Bureau of Standards.
Page 898 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE RANSPONDER LTITUDE NCODER PERATIONAL HECKOUT Perform this procedure to do an operational checkout of the Transponder Altitude Encoder. Perform Static System Operational Check procedure starting on page 13. Perform Pitot System Operational Check procedure starting on page 14.
Page 899 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE The Primary Flight Altimeter must be calibrated per part 43 section E. Verify compliance with AC-43.13 as applicable. Set primary flight altimeter to 29.92 inches of mercury. Set the TKM Michel 3300 ATC Transponder Test Set or equivalent, to read altitude (ALT) from the transponder system.
Page 900 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 10-12 Table 34-3 and Table 34-4 have the troubleshooting information for the transponder altitude encoder. The instruction manual noted in Table 34-3 must be the latest versions of the OEM manuals listed below:...
Page 901 Periodic Maintenance Section 10-14 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Vertical Speed Indicator Procedures...
Page 902 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ERTICAL PEED NDICATOR EMOVAL Perform this procedure to remove the vertical speed indicator. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 903 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Install caps on to the end of the static line and on to the static port on the vertical speed indicator to prevent moisture from entering into the static line or vertical speed indicator. Remove (4) panel screws and remove instrument.
Page 904 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ERTICAL PEED NDICATOR NSTALLATION Perform this procedure to install the altimeter into the instrument panel. Check that all electrical switches are OFF. If installing a new airspeed indicator immediately after removing an old vertical speed indicator, then proceed to step 8 below.
Page 905 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ERTICAL PEED NDICATOR PERATIONAL HECK Perform the following procedure to check the operation of the vertical speed indicator, VSI. Referring to Figure 34-21 above, set VSI zero indication with adjustment screw shown. Check that static lines are free entrapped moisture and restrictions.
Page 906 Periodic Maintenance Section 10-18 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Airspeed Indicator Procedures...
Page 907 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE IRSPEED NDICATOR EMOVAL Perform this procedure to remove the vertical speed indicator. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 908 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Figure 34-26 Rear View of the instrument Panel Showing Location of the Airspeed Indicator Install caps on to the end of the pitot and static line and on to the pitot and static port on the airspeed indicator to prevent moisture from entering into the pitot and static line or airspeed indicator.
Page 909 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE IRSPEED NDICATOR NSTALLATION Perform this procedure to install the altimeter into the instrument panel. Check that all electrical switches are OFF. If installing a new airspeed indicator immediately after removing an old airspeed indicator, then proceed to step 8 below.
Page 910 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE IRSPEED NDICATOR PERATION HECKOUT Perform this procedure to check the operation of the airspeed indicator. Check the Static lines are free entrapped moisture and restrictions. Check the pitot lines are free entrapped moisture and restriction.
Page 911 Periodic Maintenance Section 10-22 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Outside Air Temperature Indicator/Sensor...
Page 912 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE UTSIDE EMPERATURE NDICATOR EMOVAL Perform this procedure to remove the Outside Air Temperature indicator. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 913 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE UTSIDE EMPERATURE NDICATOR NSTALLATION Perform this procedure to install the Outside Air Temperature/Clock, OAT/Clock, indicator. Check that all electrical switches are OFF. If installing a new OAT/Clock indicator immediately after removing an old OAT/Clock indicator, then proceed to step 7 below.
Page 914 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE UTSIDE EMPERATURE ENSOR EMOVAL Perform this procedure to remove the Outside Air Temperature sensor. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 915 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE UTSIDE EMPERATURE ENSOR NSTALLATION Perform this procedure to remove the Outside Air Temperature sensor. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 916 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE NIVERSAL LOCK Perform this procedure to set up the Universal Time on the clock. Refer to Figure 34-30 during this procedure. Press SEL button to select and display Universal Time (UT) Simultaneously press SEL and CTL buttons to enter set mode...
Page 917 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE OCAL Perform this procedure to set the local time on the clock. Refer to Figure 34-30 during this procedure. Press SEL button to select and display Local Time (LT) Simultaneously press SEL and CTL buttons to enter set mode...
Page 918 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE UTSIDE EMPERATURE NDICATOR ENSOR PERATIONAL HECK Perform this procedure to perform an operational check of the OAT Indicator and sensor. Refer to Figure 34-30 during this procedure. Figure 34-30 OAT / CLOCK Controls From the flight instrument panel position the aircraft master switch ON Verify display illuminates.
Page 919 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 10-24 This section has the troubleshooting information on the OAT/Clock indicator and OAT sensor. MODEL DOCUMENT TITLE NOTES M803 M803 Installation Manual Available at www.davtron.com Table 34-7 Installation Manual for the OAT/Clock System...
Page 920 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 34-10 P/N 135A-970-100 Page 52 of 116 REVISION ~...
Page 921 Periodic Maintenance Section 20-02 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Magnetic Compass Procedures Section 20-03 This section contains the removal and installation of the magnetic compass.
Page 922 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AGNETIC OMPASS EMOVAL Perform this procedure to remove the magnetic compass. Check that all aircraft electrical power is OFF Disconnect J06 compass light connector from P06 and remove wire from windshield hoop. Figure 34-31 Compass Installation Loosen and remove compass mounting screw and nut located where the compass body and mounting post meet.
Page 923 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AGNETIC OMPASS NSTALLATION Perform this procedure to install ONLY the magnetic compass installation. Ensure that the compass being installed is suitable for the hemisphere of operation. A compass equipped for the southern hemisphere will have a part number ending in-SH Install compass body to mounting post by means of mounting screw and nut.
Page 924 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AGNETIC OMPASS AND RACKET NSTALLATION Perform this procedure to install the magnetic compass and compass bracket installation. Check that the mounting surface is not less than 10 degrees C. Using the cleaning cloth contained in the sachet provided, clean the area of the windshield where the compass is to be mounted.
Page 925 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE (“S ”) P AGNETIC OMPASS OMPENSATION WING ROCEDURE Perform this procedure to perform the magnetic compass compensation. This procedure should be carried out if erratic compass function is suspected, or any time significant changes are made in the airplanes installed electrical equipment.
Page 926 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE If the aircraft compass is not in alignment with the magnetic north of the master compass, insert the corrector key into the right hand hole at the front of the compass and rotate the key in either direction so that the north point is directly under the index line.
Page 927 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE OMPASS ORRECTION ILLING 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 928 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 20-04 This section has the troubleshooting information. Complaint Possible Cause Remedy • Remove sources of Magnetic interference magnetic interference • Level Compass Compass not level Compass error • Replace Defective compass • Swing Compass Compass not swung •...
Page 929 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Attitude Gyro Section 20-05 The attitude gyro is installed in the top center of the instrument panel. Figure 34-34 Attitude Gyro Movement of the brown and blue “earth and sky” attitude display behind the fixed pointer displays aircraft pitch and roll attitude changes to the pilot.
Page 930 Periodic Maintenance Section 20-06 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Attitude Indicator Procedures...
Page 931 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE TTITUDE NDICATOR EMOVAL Perform this procedure to remove the attitude indicator. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 932 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE TTITUDE NDICATOR NSTALLATION Perform this procedure to install the attitude Indicator. Check that all electrical switches are OFF. If installing a new attitude gyro indicator immediately after removing an old attitude gyro indicator, then proceed to step 7 below.
Page 933 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE TTITUDE NDICATOR PERATIONAL HECK Perform this procedure to do an operation check of the attitude indicator. Place the following aircraft circuit breakers in the position indicated. Circuit Circuit Breaker Section Position Breaker SYSTEM GYRO CLOSED...
Page 934 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Attitude Indicator Troubleshooting Section 20-08 This section has the attitude indicator troubleshooting information. Complaint Possible Cause Remedy Defective attitude gyro circuit • Replace circuit breaker breaker Attitude gyro inoperative • Replace instrument (OFF flag visible) Defective instrument •...
Page 935 Periodic Maintenance Section 20-10 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Directional Gyro Procedures Section 20-11 This section details the instructions to remove and install the directional gyro, DG.
Page 936 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE IRECTIONAL EMOVAL Perform this procedure to remove the directional gyro. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 937 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE IRECTIONAL NSTALLATION Perform this procedure to install the directional gyro. Check that all electrical switches are OFF. If installing a new directional gyro indicator immediately after removing an old directional gyro indicator, then proceed to step 7 below.
Page 938 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE IRECTIONAL PERATIONAL HECKOUT Perform this procedure to do an operational checkout of the directional gyro. Place the following aircraft circuit breakers in the position indicated. Circuit Circuit Breaker Section Position Breaker SYSTEM GYRO CLOSED INSTRUMENTS...
Page 939 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Directional Gyro Troubleshooting Section 20-12 This section contains the troubleshooting guide for the directional gyro. Complaint Possible Cause Remedy • Replace circuit breaker Defective directional gyro circuit breaker Directional gyro inoperative • Replace instrument (OFF flag visible) Defective instrument •...
Page 940 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 34-20 P/N 135A-970-100 Page 72 of 116 REVISION B...
Page 941 Periodic Maintenance Section 20-14 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Turn Rate Gyro Procedures...
Page 942 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE EMOVAL Perform this procedure to remove the turn rate gyro. Check that all electrical switches are off. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 943 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE NSTALLATION Perform this procedure to install the turn rate gyro indicator. Check that all electrical switches are off. If installing a new turn rate gyro indicator immediately after removing an old turn rate gyro indicator, then proceed to step 7 below.
Page 944 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PERATIONAL HECKOUT Perform this procedure to do an operational checkout of the turn rate gyro. Place the following aircraft circuit breakers in the position indicated. Circuit Circuit Breaker Section Position Breaker SYSTEM GYRO CLOSED INSTRUMENTS...
Page 945 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Turn Coordinator Gyro Troubleshooting Section 20-16 Table 34-18 Section 34-00contains the troubleshooting guide for the turn rate gyro. Complaint Possible Cause Remedy • Replace circuit breaker Defective turn coordinator circuit breaker Turn coordinator inoperative • Replace instrument (“OFF”...
Page 946 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 34-20 P/N 135A-970-100 Page 78 of 116 REVISION B...
Page 947 Course Deviation Indicator (CDI) displays providing Localizer and Glideslope position information to the pilot. VOR/Localizer Receiver Section 30-01 The Liberty XL-2 offers five avionics units with localizer reception capability: • Garmin Model GNS 430 COM/NAV/GPS Receiver • Garmin Model GNS 530 COM/NAV/GPS receiver •...
Page 948 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AVIGATION ECEIVER EMOVAL Perform this procedure to remove any of the navigation receivers. Check that all electrical switches are off. Locate small installation/removal hole on front face of affected component (location varies). Insert hex key (size varies with avionics manufacturer) into hole and turn counterclockwise as many turns as possible without force.
Page 949 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AVIGATION ECEIVER NSTALLATION Perform this procedure to install any of the navigation receivers. Check that all electrical switches are off. Locate small installation/removal hole on front face of component (location varies). Insert hex key and ensure that installation screw has been “backed out”...
Page 950 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AVIGATION NTENNA EMOVAL Perform this procedure to remove the navigation antenna. Remove all power from the aircraft Remove VOR/Glideslope antenna cover screws (6) Carefully slide the cover and attached antenna assembly vertically until access to the antenna cable BNC connector is obtained. Prior to disconnection of the BNC connector inspect assembly for damage.
Page 951 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE VOR/LOC/GS Antenna COAX Cable Figure 34-42 VOR/LOC/GS Slope Antenna Installation (135A-82-103) This completes the Navigation Antenna Removal procedure. 34-30 P/N 135A-970-100 REVISION ~ Page 83 of 116...
Page 952 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AVIGATION NTENNA NSTALLATION Perform this procedure to install the navigation antenna. Remove power from the aircraft Install antenna base element in the cover assembly using retaining hardware. Refer to diagram above for assembly sequence. Position the cover over the vertical fin and connect BNC connector to antenna base element.
Page 953 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE AVIGATION YSTEM PERATIONAL HECKOUT Perform the post installation procedure using the Garmin Ltd OEM installation manual to do an operation checkout of the navigation system. Use Table 34-19 for the applicable Garmin manual to use.
Page 954 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 30-04 This section has the information to troubleshoot issues with the navigation system. MODEL DOCUMENT TITLE NOTES GNS 430 190-00140-00 USER GUIDE Available at www.garmin.com 190-00140-02 INSTALLATION MANUAL Contact Garmin Dealer GNS 530...
Page 955 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Glideslope Receiver Section 30-05 The Liberty Aerospace, Inc. XL-2 airplane offers five avionics units with an integrated Glideslope reception capability: • Garmin Model GNS 430 COM/NAV/GPS Receiver • Garmin Model GNS 530 COM/NAV/GPS Receiver •...
Page 956 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE LIDESLOPE PERATIONAL HECKOUT Perform the post installation procedure using the Garmin Ltd OEM installation manual to do an operation checkout of the navigation system. Use Table 34-22 for the applicable Garmin manual to use. MODEL...
Page 957 Section 30-09 The Marker Beacon receiver and three-light display are incorporated in the Garmin audio selection and switching panel model GMA 340 standard on the XL-2. All marker signals are received on a single common frequency of 75 MHz. Figure 34-44...
Page 958 The market beacon receiver is integrated in the audio panel. Removal and replacement procedures for the audio panel can be found in Liberty Maintenance Manual Chapter 23 – Communications.
Page 959 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ARKER EACON NTENNA EMOVAL Perform this procedure to remove the marker beacon antenna. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 960 Clean the surface with acetone and clean, lint free rags. Do not allow the acetone to air dry on the bonding surfaces. Dry the solvent using clean, lint free rags. Liberty Aerospace, Inc. recommends the use of two hands, one with a solvent dampened rag, and one following with a dry rag.
Page 961 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Silastic, RTV or Silicone-Based sealing/caulking compounds are not to be used around the base or over the screw fillets. The high dielectric content of these materials distort satellite reception at low angles of elevation. Figure 34-47 Marker Beacon Antenna Conductive Sealant Mount the antenna using screws, washers, nuts and backing plate.
Page 962 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE ARKER EACON PERATIONAL HECKOUT Perform the post installation procedure using the Garmin Ltd OEM installation manual to do an operation checkout of the navigation system. Use Table 34-25 for the applicable Garmin manual to use.
Page 963 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 30-12 This section has the information to troubleshot issues with the navigation system. MODEL DOCUMENT TITLE NOTES GMA 340 190-00149-10 USER GUIDE Available at www.garmin.com 190-00149-01 INSTALLATION MANUAL Contact Garmin Dealer Table 34-26...
Page 964 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 34-30 P/N 135A-970-100 Page 96 of 116 REVISION ~...
Page 965 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Section 34-50 Dependent Position Determining The airplane may be equipped with avionics system installations that provide dependent position determination as well as approach and landing guidance based on signals from ground stations (VOR, ILS) and the satellite-based Global Positioning System (GPS).
Page 966 Figure 34-49 GNS Model and Software Verification Two GPS antennas are installed on the XL-2. A compound antenna installation is utilized that contains both a GPS reception antenna and a COM antenna. A forward antenna is assigned to the GPS receiver in the COM/NAV 1 avionics stack position.
Page 967 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE GPS Receiver Procedures Section 50-03 The GPS receivers and antennas are integral to the COM/NAV receivers and antennas. The procedures for removing and installing the receivers and/or antennas are in Chapter 23 – Communications. 34-50...
Page 968 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE GPS S YSTEM PERATIONAL HECKOUT Perform the post installation procedure using the Garmin Ltd OEM installation manual to do an operation checkout of the navigation system. Use Table 34-28 for the applicable Garmin manual to use.
Page 969 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 50-04 This section has the information to troubleshot issues with the navigation system. MODEL DOCUMENT TITLE NOTES GNS 430 190-00140-00 USER GUIDE Available at www.garmin.com 190-00140-02 INSTALLATION MANUAL Contact Garmin Dealer GNS 530...
Page 970 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Transponder Section 50-05 The Garmin GTX 327 is a panel-mounted transponder with the addition of altitude reporting and timing functions. The transponder is a radio transmitter and receiver that operates on radar frequencies, receiving ground radar or TCAS interrogations at 1030 MHz and transmitting a coded response of pulses to ground-based radar on a frequency of 1090 MHz.
Page 971 Periodic Maintenance Section 50-06 Periodic maintenance of this unit entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Additional calibration testing is required at intervals to remain in compliance with 14 CFR Part 91 requirements.
Page 972 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE RANSPONDER NTENNA EMOVAL Perform this procedure to remove the transponder antenna. Before starting this procedure, the tail of the airplane requires support. Failure to support the airplane’s tail may cause damage to the airplane’s tail section while accessing any area aft of the passenger compartment.
Page 973 Clean the surface with acetone and clean, lint free rags. Do not allow the acetone to air dry on the bonding surfaces. Dry the solvent using clean, lint free rags. Liberty Aerospace, Inc. recommends the use of two hands, one with a solvent dampened rag, and one following with a dry rag.
Page 974 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Run a bead of white, non-corrosive RTV (Dow Corning 748, or equivalent) around the base of the antenna. Fillet the edges for a neat installation. Connect the Transponder coax antenna lead. Check continuity between a mounting screw and the chassis for <0.5 ohms resistance (0.003 ohms is ideal).
Page 975 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE RANSPONDER YSTEM PERATIONAL HECKOUT Perform an operational check using Garmin Ltd. OEM installation manual Post Installation Checkout procedure. Refer to the table below for applicable manual and section. In all cases, the latest manual version is to be used.
Page 976 Course Deviation Indicators Section 50-09 The XL-2 can be fitted with two models of Course Deviation Indicator (CDI) depending on which radio options have been installed. Refer to the configuration table below for identification of CDI models with radios installed.
Page 977 The Garmin GI-106A Course Deviation Indicators are designed to operate with VHF and GPS navigational equipment to provide VOR, Localizer (LOC) and Glideslope (GS) information to the pilot. XL-2 radio configurations utilizing a Garmin GNS 430 or GNS 530 COM\/NAV/GPS radio us the GI-106A CDI.
Page 978 Periodic Maintenance Section 50-10 Periodic maintenance of these units entails operational checks and inspections performed at intervals specified in the Liberty Maintenance Manual, Chapter 05 and in accordance with the operational check and inspection procedure in this section. Course Deviation Indicator Procedures...
Page 979 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE OURSE EVIATION NDICATOR EMOVAL Perform this procedure to remove the course deviation indicator. Check that all electrical switches are OFF. Place a cover over the pilot yoke control. Have a large block of soft foam on your lap to place the instrument panel Remove the ten screws securing the instrument panel to the instrument console.
Page 980 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Secure the cutout (bezel) light assembly to the panel to prevent damage to the assembly. If the installation of the course deviation indicator will take place later, install the instrument panel in to the instrument console. Secure the instrument panel with the ten screws removed in step 4 above.
Page 981 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE OURSE EVIATION NDICATOR NSTALLATION Perform this procedure to install the course deviation indicator or CDI. Check that all electrical switches are OFF. If installing a new CDI immediately after removing an old CDI, then proceed to step 8 below.
Page 982 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE OURSE EVIATION NDICATOR PERATIONAL HECKOUT Perform an operational check using Garmin Ltd. OEM installation manual Post Installation Checkout procedure. Refer to the table below for applicable manual and section. In all cases, use the latest manual version.
Page 983 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE Troubleshooting Guide Section 50-12 Troubleshooting of the CDI's is by reference to the latest versions of the Garmin manuals listed below. MODEL DOCUMENT TITLE NOTES GNS 430 190-00140-00 USER GUIDE Available at www.garmin.com 190-00140-05 INSTALLATION MANUAL...
Page 984 NAVIGATION AND PITOT/STATIC XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 34-50 P/N 135A-970-100 Page 116 of 116 REVISION ~...
Page 985 Standard Practices - Structures XL-2 AIRPLANE CHAPTER 51 Standard Practices - Structures Chapter 51 P/N 135A-970-100 REVISION ~ Page 1 of 74...
Page 986 XL-2 AIRPLANE Copyright © 2009 All rights reserved. The information contained herein is proprietary to Liberty Aerospace, Incorporated. It is prohibited to reproduce or transmit in any form or by any means, electronic or mechanical, including photocopying, recording, or use of any information storage and retrieval system, any portion of this document without express written permission of Liberty Aerospace Incorporated.
Page 987 Standard Practices - Structures XL-2 AIRPLANE Table of Contents 51-00 ECTION ENERAL 00-01 ECTION UALIFIED ACILITIES OCUMENTATION 51-10 ECTION TRUCTURAL OMPOSITE EPAIRS 10-01 ECTION XTENSIVE USELAGE LYING URFACE EPAIR 10-02 ECTION ITTINGS EQUIRING IGGING OSITIONAL OCATION 51-11 ECTION OMPOSITES OLID...
Page 988 Standard Practices - Structures XL-2 AIRPLANE ISBOND OF DHESIVE OINT EPAIR IDES DHESIVE OINT AMINATE AMINATE 2 REPAIR O DHESIVE OINT ANDWICH ANDWICH -3 D AMAGE EPAIR ROCEDURE 51-20 ECTION INOR TRUCTURAL ETALLIC EPAIRS 20-01 ECTION ENERAL ORROSION NSPECTION ETAL...
Page 989 If the mechanic is unable to make the decision due to a lack of data, Liberty Aerospace Inc. customer support will furnish this data to help the mechanic make the major/minor determination.
Page 990 Standard Practices - Structures XL-2 AIRPLANE o Interior structures that carry crash loads, as required by 14 CFR, part 23, FARs 23.561 and 23.562 are primary structure. These are the primary load carrying members. Their failure would reduce the structural integrity of the airframe.
Page 991 Standard Practices - Structures XL-2 AIRPLANE Part Number Description 135A-10-123 Door Frame Assembly, Port* 135A-10-124 Door Frame Assembly, Starboard* 135A-10-407 Belly Fairing 135A-10-487 Inner Door Frame Port 135A-10-488 Inner Door Frame Starboard 135A-11-401 Footstep Hard point - Port 135A-11-402 Footstep Hard point – Starboard...
Page 992 Qualified Facilities And Documentation Section 00-01 Repairs to the Liberty XL-2 composite components (sandwich and solid laminate) or metal components may be carried out by any appropriately rated composite repair facility familiar with primary structural composite repairs. Example repair processes are delineated in the later section of this chapter.
Page 993 XL-2 AIRPLANE Section 51-10 Structural Composite Repairs The fuselage of the Liberty XL-2 is composed of structural composite materials. The fuselage aft of the engine cowling is fabricated from carbon fiber reinforced fabrics that are used as facing plies adhered to core materials to form a structural sandwich.
Page 994 Standard Practices - Structures XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 51-10 P/N 135A-970-100 Page 10 of 74 REVISION ~...
Page 995 Section 51-11 Composites - Solid Laminate And Sandwich Construction The majority of the fuselage of the Liberty XL-2 is carbon fiber reinforced sandwich construction. Different thicknesses of core material are used to form a structural sandwich in order to support the distribution of stresses through the structure.
Page 996 Standard Practices - Structures XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 51-11 P/N 135A-970-100 Page 12 of 74 REVISION ~...
Page 997 • Damage number (per unit length / area) Critical damage dimensions have been determined for the Liberty XL-2 fuselage. The acceptable limit for the quantity of ‘damage’ per unit length or area has also been determined. This allows the fuselage damage to be specified as one of four with each types (1 –...
Page 998 Type 1 - Damage Section 12-01 The definition of Type 1-damage is critical damage inflicted to primary or secondary structure at locations such as highly stressed (contact Liberty Aerospace Customer support for clarification) regions and underlying structural elements. Damage is classified as Type 1 when the size, location, and number of damages per unit length or area endanger the structural integrity of the aircraft.
Page 999 Standard Practices - Structures XL-2 AIRPLANE Type 3 - Damage Section 12-03 The definition of Type 3-damage is damage limited to outer skin only (no damage to internal facing plies or core material). Damages are classified Type 3 when the size, location and number of damage per unit length/area does not endanger the structural integrity of the aircraft.
Page 1000 Standard Practices - Structures XL-2 AIRPLANE PAGE LEFT INTENTIONALLY BLANK 51-12 P/N 135A-970-100 Page 16 of 74 REVISION ~...
Page 1001 A&P Mechanic. For example, if tap testing is required and a defect is found, it may be necessary to use ultrasound to fully define the defect. Liberty Aerospace Inc Customer Support must be contacted to obtain these additional inspection instructions.

Liberty XL-2 Maintenance Manual

Table of Contents

Section 07-00 General/Section 07-10 Lifting and Jacking

/243 Mhz Elt Service Procedures Section 60-10

Aileron Procedures Section 10-01

Rudder Procedure Section 20-01

Section 30-00 General/Section 30-30 Pitot-Static System

Section 52-00 General/Section 52-02 Emergency

Section 52-00 General

Section 52-02 Emergency

Doors

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