ALTERNATOR FUSE HOLDER F3 INSTALLATION PRODUCT IMPROVEMENT ALTERNATOR FUSE F3 INSTALLATION UPGRADE RECOMMENDED

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1 REASON FOR ACTION PURPOSE COMPLIANCE PRODUCT IMPROVEMENT ALTERNATOR FUSE F3 INSTALLATION UPGRADE RECOMMENDED MODELS AFFECTED ALL LIBERTY XL-2 AIRCRAFT SN 0014 & 0132 OBJECTIVE: Liberty Aerospace has identified product improvements for the engine case mounted alternator fuse F3. Upgrades recommended by this SSI secure fuse holder F3 to the engine case in an orientation determined to be best suited for long term serviceability. In addition, fuse holder F3 wire termination upgrade from crimp to solder is also recommended for long term serviceability. APPLICABLE DOCUMENTS: Use the following documents as a reference while conducting the procedures in this document. QQ-S-571 Solder, Tin Alloy, Tin-Lead Alloy, and Lead Alloy MIL-S Soldering, Manual Type, High Reliability, Electrical and Electronic Equipment MIL-F Flux, Soldering, Liquid (Rosin Based) MIL-STD-202 Test Methods for Electronic and Electrical Component Parts 135A Liberty XL2 Maintenance Manual FUSE HOLDER LOCATION: The forward cable assembly, PN 135A , has an inline fuse holder. The fuse holder s location is just behind and below the alternator on the engine (behind the baffle). This fuse holder is connected to wires P26D16 and P26E16 by either a crimp or a solder joint. INSPECTION: 1. Remove the upper and lower engine cowling in accordance with Chapter 53 Fuselage of the Airplane Maintenance Manual. 2. Remove the nut, washers and bolt securing the fuse holder P clamp. 3. Disconnect wire P26E16 from the alternator AUX terminal stud. -R15-Fuseholder F3.doc of s 1 8 A

2 4. Remove the P clamp from the engine and fuse holder. 5. Inspect both ends of the fuse holder termination and determine if the termination is crimp or solder as shown in Figure 1. < Inches > Inches Figure 1 - Solder or Crimp Termination Identification The photograph in Figure 1 above shows how to visually identify a crimp or solder fuse termination. A crimp termination can be identified by a deformed asymmetrical barrel typically measuring less than inches across. A solder termination can be identified as symmetrical barrel typically measuring greater than inches across. -R15-Fuseholder F3.doc of s 2 8 A

3 6. If the fuse holder wire terminations are cylindrical and symmetric, as shown in Figure 1, indicating a soldered termination, proceed to step If the fuse holder terminations appear flattened, deformed or asymmetrical, as shown in Figure 1, proceed to the Upgrade Procedure section of this SSI. 8. Install the long end of the fuse holder into the P clamp. 9. Mount the P clamp such that the flat surface away from the engine using hardware removed previously as shown in Figure Recheck the location of all wires and components to insure proper clearances. Verify no part of the fuse holder, P clamp or connecting wires are to be in contact with the engine case or forward baffle. 11. Attach wire P26E16 to the alternator AUX terminal stud. 12. Install the engine cowling in accordance with Chapter 53 Fuselage of the Airplane Maintenance Manual. UPGRADE PROCEDURE If the F3 fuse holder barrel has been crimped, perform the following procedure. A replacement fuse F3 wire assembly 135A will be required. Obtain this part from Liberty Aerospace Customer Support. 1. Remove wire P26E16 from the alternator AUX terminal stud if not already performed. 2. Remove fuse holder F3 P clamp from the engine if not already performed. 3. Cut wire P26D16 next to the end of the fuse holder. 4. Remove wire and fuse holder assembly from the aircraft and discard. 5. Strip ½ inch of insulation from wire P26D16. Tin the wire per MIL-S Soldering, Manual Type, High Reliability, Electrical and Electronic Equipment. -R15-Fuseholder F3.doc of s 3 8 A

4 6. Thread the new heat shrink on to the wire and temporally secure it away from the work area. 7. Locate replacement fuse F3 wire assembly 135A Apply a small amount of liquid rosin flux to the replacement assembly un-terminated fuse holder barrel. 9. Solder the wire P26D16 into the fuse holder solder barrel per MIL-S Soldering, Manual Type, High Reliability, Electrical and Electronic Equipment. See Figure 2. Figure 2 - Acceptable Fuse F3 Solder Joint 10. After the solder has cooled, clean away any excess flux from the soldered joint. 11. Slide the new heat shrink down over the wire and solder cup from the fuse holder. 12. Apply sufficient heat from a heat gun to shrink the new heat shrink tubing. 13. Mount the P clamp to the long end of the fuse holder. -R15-Fuseholder F3.doc of s 4 8 A

5 14. Mount the P clamp and fuse holder to the engine baffle with the flat surface of the clamp away from the engine as shown in Figure 3. Use the bolt, washers and nut removed previously. Figure 3 - Fuse F3 Mounting -R15-Fuseholder F3.doc of s 5 8 A

6 15. Attach wire P26E16 to the alternator AUX terminal stud. 16. Check the location of all wires and components to insure proper clearances. Verify no part of the fuse holder, P clamp or connecting wires are in contact with the engine case or forward baffle. 17. Install the engine cowling in accordance with Chapter 53 Fuselage of the Airplane Maintenance CUSTOMER SUPPORT Please contact Liberty Aerospace, Inc., to request the shipment of the components required for this procedure. The cost of the components and shipping is covered by Liberty Aerospace, Inc. The labor cost of performing this procedure within this Special Service Information letter is not covered under Warranty or by Liberty Aerospace, Inc. Please enter this procedure in your aircraft log book. Please complete and return this page by scanned , regular mail, or FAX, indicating this has been received and all actions have been taken to comply with it. -R15-Fuseholder F3.doc of s 6 8 A

7 COMPLIANCE CONFIRMATION Please complete and return this page by scanned , regular mail, or FAX, indicating this has been received and all actions have been taken to comply with it. This document shall be returned to Liberty Aerospace. Regular Mail: ATTN: Customer Support Liberty Aerospace Melbourne, FL Or FAX: Liberty Aircraft Serial Aircraft Tach Hours At Time Of Modification Modification Completion Date Owner/Operator s Name Owner/Operator s Address Telephone s Owner/Operator s Signature -R15-Fuseholder F3.doc of s 7 8 A

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