Liberty XL-2 User manual

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WITHOUT EXPRESS WRITTEN PERMISSION OF LIBERTY AEROSPACE INC.
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Liberty
Technical
Document
Document Number: 135A-970-100
Revision: E
Liberty XL-2 Airplane
Maintenance Manual

PREFACE
XL-2 AIRPLANE
Preface P/N 135A-970-100
Page ii REVISION E
PAGE LEFT INTENTIONALLY BLANK

PREFACE
XL-2 AIRPLANE
P/N 135A-970-100 Preface
REVISION E Page iii
Preface
Liberty Aerospace provides Instructions for Continued Airworthiness based on the
design, testing, and certification of the XL-2 aircraft which Liberty Aerospace is the
holder of the Type Certificate (TC) issued by the Federal Aviation Administration
(FAA). Instructions in this Liberty manual, which include maintenance, repair limits,
overhaul, and installation, are applicable only to the Liberty XL-2 model aircraft.
This manual, applicable service documents, and other related publications
constitute the Instructions for Continued Airworthiness (ICA) prepared by Liberty
Aerospace and reviewed by the FAA. Pursuant to Federal Aviation Regulation
(FAR) § 43.13, each person performing maintenance, alteration, or preventive
maintenance on the airframe, engine or accessories must use methods,
techniques, and practices prescribed in the Instructions for Continued
Airworthiness.
Except for FAR part 43.3 authorized owner maintenance, Liberty Aerospace
has written the ICA for exclusive use by FAA (or equivalent authority)
licensed mechanics or FAA (or equivalent authority) certified repair center
employees working under the supervision of an FAA licensed mechanic.
Information and instructions contained in this manual anticipate the user
possesses and applies the knowledge, training, and experience
commensurate with the requirements to meet the prerequisite FAA license
and certification requirements. No other use is authorized.
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. Do not use Liberty Aerospace ICA for such parts.
Service Documents may contain advance changes to the ICA. It is the
responsibility of the organization/person maintaining or operating the aircraft to
verify that current and complete information, including Service Bulletins, FAA
Airworthiness Directives (AD), and publications are used.
To facilitate the use of current data, Liberty Aerospace provides information via the
Internet on www.libertyaircraft.com. The information available includes a listing
of the latest manual versions, service bulletins, FAA ADs, and other information
applicable to the Instructions for Continued Airworthiness. This information is free
of charge to owners of Liberty Aerospace aircraft by registering through Owner
Support.

PREFACE
XL-2 AIRPLANE
Preface P/N 135A-970-100
Page iv REVISION E
Table of Contents
PREFACE III
TABLE OF CONTENTS IV
SUPERSEDE NOTICE V
LIST OF EFFECTIVE PAGES V
HIGHLIGHT OF REVISIONS VII
RECORD OF REVISION X
LIST OF SERVICE BULLETINS XI
SERVICE BULLETINS RELEASED AFTER PUBLICATION XIII
TABLE OF CHAPTERS XV

PREFACE
XL-2 AIRPLANE
P/N 135A-970-100 Preface
REVISION E Page v
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 REVISION DATE PAGE REVISION DATE
Preface i - xvi E 07/14/11 12-01 thru 12-02 E 07/14/11
01-01 thru 01-20 E 07/14/11 12-03 thru 12-13 ~ 07/31/09
01-05 thru 01-06 ~ 07/31/09 12-13 thru 12-14 E 07/14/11
01-07 thru 01-18 E 07/14/11 12-15 thru 12-16 ~ 07/31/09
01-18 thru 01-20 ~ 07/31/09 20-01 thru 20-02 D 02/16/11
03-01 thru 03-10 E 07/14/11 20-03 thru 20-06 ~ 07/31/09
04-01 thru 04-2 D 02/16/11 20-07 thru 20-16 D 02/16/11
04-03 thru 04-6 ~ 07/31/09 20-17 thru 20-26 ~ 07/31/09
04-07 thru 04-20 D 02/16/11 21-01 thru 21-40 ~ 07/31/09
04-21 thru 04-22 ~ 07/31/09 23-01 thru 23-04 D 02/16/11
05-01 thru 05-02 D 02/16/11 23-05 thru 23-08 ~ 07/31/09
05-03 thru 05-08 ~ 07/31/09 23-09 thru 23-38 D 02/16/11
05-09 thru 05-34 D 02/16/11 23-39 thru 23-44 ~ 07/31/09
05-35 thru 05-42 ~ 07/31/09 24-01 thru 24-02 E 07/14/11
05-43 thru 05-52 C 06/21/10 24-03 thru 24-04 E 07/14/11
06-01 thru 06-08 ~ 07/31/09 24-05 thru 24-08 E 07/14/11
07-01 thru 07-02 E 07/14/11 24-09 thru 24-16 ~ 07/31/09
07-03 thru 07-04 ~ 07/31/09 24-17 thru 24-44 E 07/14/11
07-05 thru 07-14 E 07/14/11 24-45 thru 24-62 D 02/16/11
08-01 thru 08-16 ~ 07/31/09 25-02 thru 25-04 C 06/21/10
09-01 thru 09-12 ~ 07/31/09 25-05 thru 25-10 ~ 07/31/09
10-01 thru 10-12 ~ 07/31/09 25-11 thru 25-66 D 02/16/11
11-01 thru 11-2 E 07/14/11 27-01 thru 27-02 E 07/14/11
11-03 thru 11-12 ~ 07/31/09 27-03 thru 27-06 ~ 07/31/09
11-13 thru 11-34 E 07/14/11 27-07 thru 27-34 D 02/16/11
11-34 thru 11-38 ~ 07/31/09 27-35 thru 27-60 E 07/14/11
27-61 thru 27-76 D 02/16/11
27-77 thru 27-84 D 02/16/11
27-84 thru 27-100 D 02/16/11
27-101 thru 27-120 ~ 07/31/09

PREFACE
XL-2 AIRPLANE
Preface P/N 135A-970-100
Page vi REVISION E
PAGE REVISION DATE PAGE REVISION DATE
28-01 thru 28-02 E 07/14/11 70-01 thru 70-06 ~ 07/31/09
28-03 thru 28-17 B 01/30/10 71-01 thru 71-02 E 07/14/11
28-17 thru 28-36 E 07/14/11 71-03 thru 71-64 ~ 07/31/09
28-37 thru 28-56 ~ 07/31/09 71-65 thru 71-76 E 07/14/11
30-1 thru 30-20 C 06/21/10 71-77 thru 71-74 ~ 07/31/09
31-01 thru 31-54 ~ 07/31/09 72-01 thru 72-30 ~ 07/31/09
32-01 thru 32-02 E 07/14/11 73-01 thru 73-38 ~ 07/31/09
32-03 thru 32-18 ~ 07/31/09 74-01 thru 74-02 B 01/30/10
32-19 thru 32-78 E 07/14/11 74-03 thru 74-12 ~ 07/31/09
32-79 thru 32-88 ~ 07/31/09 74-13 thru 74-20 B 01/30/10
33-01 thru 33-02 C 01/30/10 75-01 thru 75-08 ~ 07/31/09
33-03 thru 33-06 ~ 07/31/09 76-01 thru 76-18 ~ 07/31/09
33-07 thru 33-22 B 01/30/10 77-01 thru 77-02 C 06/21/10
33-23 thru 33-40 C 06/21/10 77-03 thru 77-06 ~ 07/31/09
34-01 thru 34-02 B 01/30/10 77-07 thru 77-34 C 06/21/10
34-03 thru 34-52 ~ 07/31/09 78-01 thru 78-16 ~ 07/31/09
34-53 thru 34-78 B 01/30/10 79-01 thru 79-28 ~ 07/31/09
34-79 thru 34-116 ~ 07/31/09 80-01 thru 80-04 B 01/30/10
51-01 thru 51-74 ~ 07/31/09 80-05 thru 80-08 ~ 07/31/09
52-01 thru 52-30 ~ 07/31/09 80-09 thru 80-14 E 07/14/11
53-01 thru 53-04 B 01/30/10 91-01 thru 91-02 C 06/21/10
53-05 thru 53-08 ~ 07/31/09 91-03 thru 91-12 ~ 07/31/09
53-09 thru 53-22 E 07/14/11 91-13 thru 91-80 C 06/21/10
53-23 thru 53-24 ~ 07/31/09
53-25 thru 53-30 B 01/30/10
53-31 thru 53-32 ~ 07/31/09
55-01 thru 55-02 D 02/16/11
55-03 thru 55-04 B 01/30/10
55-05 thru 55-06 ~ 07/31/09
55-07 thru 55-28 D 02/16/11
55-29 thru 55-30 ~ 01/30/10
56-01 thru 56-04 B 01/30/10
56-05 thru 56-10 ~ 07/31/09
56-11 thru 56-36 E 07/14/11
56-36 thru 56-56 ~ 07/31/09
57-01 thru 57-34 D 02/16/11
61-01 thru 61-12 ~ 07/31/09

PREFACE
XL-2 AIRPLANE
P/N 135A-970-100 Preface
REVISION E Page vii
Highlight of Revisions
Revision Revision
Date Chapter Description
IR 07/31/2009 ALL Initial release of the entire manual 135A-970-100.
A 10/28/2009 04 Incorporated approved firewall blanket life extension.
B 01/30/2010 00 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). Added
Highlight of Revisions table.
05 Updated exhaust system inspection procedure.
23 Updated antenna mounting hardware callout in
compliance with current design.
25 Updated ELT antenna remove/install procedures.
27 Added drawing and procedure steps to clarify control
yoke ground installation.
28 Updated fuel boost pump remove/install and test
procedure. Added procedure steps for boost pump
control switch remove/install. Added fuel system
operational check procedure steps. Added Fuel System
Troubleshooting chart. Updated the flow of the
procedures to match other chapter is the manual.
33 Updated strobe power supply circuit breaker call out in
compliance with current design and SID-09-001.
34 Added note to compass swing procedure for
identification of northern and southern hemisphere
compass units.
53 Added belly panel remove/install procedure steps.
55 Added horizontal stabilizer inspection steps.
56 Removed procedure steps duplicated elsewhere and
directed reader to the steps.
74 Added pointer to FADEC system checks procedure.
75 Chapter removed as content is redundant to another
chapter.
77 Deleted note incorporating hardware call out in work
step.
80 Added cold start steps in accordance with TCM
operations procedures.
91 Drawings updated in accordance with current approved
design changes.

PREFACE
XL-2 AIRPLANE
Preface P/N 135A-970-100
Page viii REVISION E
Revision Revision
Date Chapter Description
C 06/21/2010 00 Updated the List of effected Pages to include new
chapter 30.
04 Added Life Limits for Fire Extinguisher. Re-formatted
the tables for readability .
05 Added inspection points for fire extinguisher.
Added inspection points for bolts associated with the
stabilizer.
Added inspection points for the alternate air valve
cabling.
Clarified the 500 hour engine inspection.
Added definitions to Hard Landing and Crash.
30 All new chapter.
33 Added procedures for the LED Wing Tip Light Fixtures.
55 Add inspection information and inspection notes for
stabilizer bolt length.
77 Removed procedures for the Pitot/Static Blade and
heater. Procedures were moved to Chapter 30.
91 Updated Schematic Figure 91-18 to include the LED
Wing Tip Light Fixture.
D 02/16/2011 00 Added information about incorporation of SSI-10-001.
04 Added Life Limits for the exhaust.
Added part numbers for the replacement exhaust.
muffler to table 04-3.
Added mandatory inspection for the aft weldment clevis
pins for both port and starboard.
Added additional mandatory inspection for the aft
weldment clevis pins for both port and starboard on SN
0009, 0116, 0117, and 0119.
05 Redefined the inspections for the batteries in the ELT
and the ELT Remote Switch.
Split the inspections requirements for the wing pins,
wing box, and aileron quick disconnect assemblies to
account for the 100-hour inspections that does not
remove the wings and the annual inspection that does
remove the wings.
Breaking out inspections for the spar attachment lugs,
pins, flap-spigot, and the locking mechanisms.
20 Updated the procedures to torque castellated nuts.
23 Added reference to Chapter 27 for the remove and
installation of the push-to-talk switch/button.
24 Added information on the F3 Alternator Fuse (SSI-10-
001).
Added a procedure to replace the F3 Fuse.
Added information to clarify what instruments will
continue to operate in the event of a primary battery
failure.

PREFACE
XL-2 AIRPLANE
P/N 135A-970-100 Preface
REVISION E Page ix
Revision Revision
Date Chapter Description
25 Correctly point to the battery limits for the ELT batteries
to Chapter 05 (was Chapter 04).
27 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.
55 Updated the procedures to torque castellated nuts.
57 Rewrote the entire chapter with a new layout of the
sections.
Added information in the removal and installation of the
anti-chafing tape for the wing root fairing.
E 07/14/2011 01 Updated Information in the Revision Tracking
paragraph.
Updated table with new AFM part numbers.
Corrected Figure 01-1.
Rewrote Section 01-40.
03 Rewrote entire chapter.
07 New images, graphics and photos.
Updated the procedure for lifting airplane.
11 Added the part numbers for the Japanese placards.
Figure 11-23 – Updated figure.
Figure 11-25 – Corrected the S/N for factory gross
weight.
12 Added wing pins to Table 12-3.
24 Figure 24-4 Redrew figure.
Figure 24-12 Corrected battery callout in figure.
Page 38 – Reworded paragraph
27 Pages 52 and 56 corrected battery callout for
secondary battery.
28 Correct relay callout on page 34
32 Added procedures to cover new parking brake.
Updated graphics.
53 Corrected battery callout for secondary battery.
56 Page 16 – removed broken link.
Page 34 – New step added for correct callout of post
install inspections.
71 Added new procedures for alternate air valve.
80 Pages 12 and 14 Corrected callouts for the primary and
secondary batteries.

PREFACE
XL-2 AIRPLANE
Preface P/N 135A-970-100
Page x REVISION E
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. Complete the table below when you have put the revision in the
AMM.
Record of Revisions
Revision Date Issued Inserted On Inserted
By Revision Date Issued Inserted On Inserted By
A 10/28/2009 10/28/2009 LAI
B 01/30/2010 01/30/2010 LAI
C 06/21/2010 06/21/2010 LAI
D 02/16/2011 02/16/2011 LAI
E 07/14/2011 07/14/2011 LAI